Smart sport device

ABSTRACT

An Internet of Thing (IoT) sport device includes a body with a processor, a camera and a wireless transceiver coupled to the processor.

BACKGROUND

The present invention relates to the Internet of Things (IoT).

The world's top sports include the following. Soccer is the biggestglobal sport and a top 10 sport in all countries measured, as well asthe dominant sport in South America, Europe and Africa. The world cupfinal is watched by an estimated 600 million people and the annual finalby more than 300 million. Basketball is a massive sport in US and China,as well as major across continental Europe and South America, making itone of the biggest global sports. Tennis is probably the world's mostuniversal sport being in the top 7 sports in every single countrymeasured and a major sport of interest in Asia, Europe, Australia, Latinand North America, thus making it 3rd in world's biggest sports. Cricketdominates sports media coverage for around a quarter of the world'spopulation in the Indian sub-continent. Also huge in UK, Australia andSouth Africa. 2011 world cup final watched by more than 400 millionglobally and semi-final between Pakistan and India by reported 1billion. Baseball is a huge sport in 2 economic powerhouses of US andJapan, being the biggest sport in the latter. American Football is thebiggest sport in the US, with popularity fueled by the US domesticmarket, where the Superbowl is regularly the most watched annual event.Car racing is a major sport in Europe and US. Golf is a major sport inUS, Japan, Korea, and UK. Ice Hockey is the biggest sport in Canada,Russia, and the US, making it the biggest winter sport. Other popularsports include boxing, badminton, volleyball, cycling, swimming,snooker, martial arts, rugby, motorbike, hockey, table tennis, horseracing, gymnastics, handball, figure skating, wrestling, skiing, diving,skating, archery, sailing, wrestling, fencing, equestrian, rowing,surfing, Beach Volleyball, Pool/Billiards, Lacrosse, Windsurfing, Polo,Tenpin Bowling, Racquetball, Competitive Climbing, Mountain Biking,among others.

In various sports such a baseball, tennis and golf, proper stroke is keyto success. Swing fluidity alongside improved movement, balance, andprecise positioning at the proper distance to each ball is important intennis. Correspondingly, one of the most difficult decisions a golfermust make when playing golf is the selection of one of their golf clubsto use for each stroke during a golf game. This decision is repeatedlymade for each stroke in view of the relatively large number of golfclubs that are used to play golf. The impact of each different golf clubagainst the golf ball will result in a different carrying distance ofthe golf ball and therefore it is extremely important for a golfer toselect the most suitable golf club to use for each shot. Moreover, eachgolf club is often used in one of several possible clock or swingpositions. The carrying distance of the golf ball when struck by thesame golf club will vary as a function of the swing position. It istherefore important for the golfer to select not only the most suitablegolf club to use for each shot, but also the swing position in which touse the selected golf club.

SUMMARY

In one aspect, an Internet of Thing (IoT) device for sport deviceingincludes thistles, a light source; sensors including a camera; aprocessor coupled to the light source and the sensor; and a wirelesstransceiver coupled to the processor.

These and other features of the present invention will become readilyapparent upon further review of the following specification anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates an exemplary environment for communicating data froma monitoring device to external computers

FIG. 1B is a perspective view of an exemplary IoT sport device system.

FIG. 1C is an exemplary process supported by the device according to thepresent invention.

FIG. 2A is a block diagram of an electronic circuit for a smart device.

FIG. 2B is a block diagram of a big data system for predicting stressexperienced by a structural unit such as a bridge, a building, or aplane, for example.

FIG. 3 is a flowchart illustrating one operation of the system of FIG.2A-2B in detecting stress on a unit.

FIG. 4 shows an exemplary sports diagnosis and trainer system foraugmented and/or virtual reality.

FIG. 5 shows an exemplary process for augmented and/or virtual realityfor viewers participating in a game.

FIG. 6 shows an exemplary process to identify reasons for sensor datachanges using a gaming process.

FIG. 7 shows an exemplary glove, FIG. 8 shows an exemplary smart band,FIG. 9 shows exemplary smart clothing, FIG. 10 shows exemplary smartballs.

FIG. 11A shows exemplary smart rackets while FIG. 11B shows electronicsin the handle for golf clubs, rackets, or kung fu sticks.

FIG. 12A-12B show exemplary protective gears, while FIG. 12C shows anexemplary process to fabricate mass-customized protective gear; andFIGS. 13A-13D show exemplary 3D fabricator of gears.

FIGS. 14A-14D show exemplary systems and techniques for manufacturing involume with a wide range of materials are disclosed for fabricatingcustom protective gears, helmets, pads, or shoes at mass customizationscale.

FIG. 15A shows an exemplary virtual reality camera mounted on a gear,and FIG. 15B shows exemplary augmented reality real-time coaching of aplayer such as a quarterback during fourth down.

FIG. 16A-16C shows exemplary coaching system for skiing, bicycling, andweightlifting/free style exercise, respectively, while FIG. 16D shows akinematic modeling for detecting exercise motion which in turn allowsprecision coaching suggestions.

Similar reference characters denote corresponding features consistentlythroughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to various embodiments of the present disclosure, anelectronic device may include communication functionality. For example,an electronic device may be a smart phone, a tablet Personal Computer(PC), a mobile phone, a video phone, an e-book reader, a desktop PC, alaptop PC, a netbook PC, a Personal Digital Assistant (PDA), a PortableMultimedia Player (PMP), an MP3 player, a mobile medical device, acamera, a wearable device (e.g., a Head-Mounted Device (HMD), electronicclothes, electronic braces, an electronic necklace, an electronicaccessory, an electronic tattoo, or a smart watch), and/or the like.

According to various embodiments of the present disclosure, anelectronic device may be a smart home appliance with communicationfunctionality. A smart home appliance may be, for example, a television,a Digital Video Disk (DVD) player, an audio, a refrigerator, an airconditioner, a vacuum cleaner, an oven, a microwave oven, a washer, adryer, an air purifier, a set-top box, a TV box (e.g., SamsungHomeSync™, Apple TV™, or Google TV™), a gaming console, an electronicdictionary, an electronic key, a camcorder, an electronic picture frame,and/or the like.

According to various embodiments of the present disclosure, anelectronic device may be a medical device (e.g., Magnetic ResonanceAngiography (MRA) device, a Magnetic Resonance Imaging (MRI) device,Computed Tomography (CT) device, an imaging device, or an ultrasonicdevice), a navigation device, a Global Positioning System (GPS)receiver, an Event Data Recorder (EDR), a Flight Data Recorder (FDR), anautomotive infotainment device, a naval electronic device (e.g., navalnavigation device, gyroscope, or compass), an avionic electronic device,a security device, an industrial or consumer robot, and/or the like.

According to various embodiments of the present disclosure, anelectronic device may be furniture, part of a building/structure, anelectronic board, electronic signature receiving device, a projector,various measuring devices (e.g., water, electricity, gas orelectro-magnetic wave measuring devices), and/or the like that includecommunication functionality.

According to various embodiments of the present disclosure, anelectronic device may be any combination of the foregoing devices. Inaddition, it will be apparent to one having ordinary skill in the artthat an electronic device according to various embodiments of thepresent disclosure is not limited to the foregoing devices.

In one embodiment, a smart device includes sensor(s) and wirelesscommunication therein. The device can detect tension and communicate toa computer for storage and analysis. The smart device provides anautomatic electronic process that eliminates the need for a manualinspection process, and uses electronic detection of stress, eliminatingsubjective human judgments and producing greater uniformity inmaintenance, inspection, and emergency detection procedures.

FIG. 1A illustrates an exemplary environment for communicating data froma monitoring device to external computers. In FIG. 1A, the monitoringdevice used for a sport device 9 includes an interface with a radiotransmitter for forwarding the result of the comparison to a remotedevice. In one example, the monitoring device may include an additionalswitch and user interface. The user interface may be used by the user inorder to trigger transmission of the comparison of the hand or footpattern reference data with the stroke patterns data to the remotedevice. Alternatively, the transmission may occur automatically eachtime the device has been used, or may be triggered by placing the sportdevice in a cradle or base. All parts of the monitoring device may beencapsulated with each other and/or may be integrated into or attachedto the body of the sport device 9. Alternatively, a radio transmittermay be arranged separately from the other parts, for instance, in abattery charger, cradle or base of the sport device 9. In that example,the interface 7 may include contact terminals in the sport device 9,which are connected to the corresponding terminals in the batterycharger for forwarding the result of the comparison via a wiredconnection to the transmitter in the battery charger or may be connectedby induction or short range wireless communications. The radiotransmitter in the battery charger then transmits this comparison resultfurther via the wireless radio connection to the remote device. In FIG.1A, the remote device may be a mobile phone 16, PDA or computer 19,which receives the information directly from the monitoring device via ashort range radio connection, as one example of a transmitter, such as aBluetooth or a Wifi or a Zigbee connection. In one example, the user ofthe remote device may receive information about how thoroughly the sportdevice 9 has been used or the need to provide a replacement sportdevice. FIG. 1A also illustrates an alternate example of a transmitter,using an intermediate receiver 17 and a network 18, such as a cellularradio system. Also in this example, the radio transmitter may be locatedin connection with the sport device 9 or alternatively in connection,with a charger, cradle or base station of the sport device 9. In such anexample, the comparison result may be transmitted via an intermediatereceiver 17 and the network 18 to a remote device 19, 16 located furtheraway than the range of a short range radio system, for example. Theremove device 19, 16 may be any device suitable for receiving thesignals from the network 18 and providing feedback on an output device.The transmission of information via a cellular radio system to theremote device may allow an advertiser provide an advertisement. Forexample, an advertisement may be added to the comparison result usingnetwork elements in the cellular radio system. The user may receive anadvertisement with the comparison result. An advantage with such asolution is that the advertiser may provide revenue offsetting all or aportion of the cost for the transmission of the comparison result fromthe sport device 9 to the remote device 19, 16.

FIG. 1B shows a block diagram of the unit 9 with processor/RAM/ROM 11.The unit 9 includes a motion sensor, a multi-axis accelerometer, and astrain gage 42. The multi-axis accelerometer may be a two-axis orthree-axis accelerometer. Strain gage 21 is mounted in the neck of theracket, and measures force applied to the ball, i.e., force in a zdirection. Acceleration and force data are acquired by themicroprocessor at a data acquisition rate (sampling rate) of from about10 to 50 samples/second, e.g., about 20 samples/second. The accelerationdata is used to infer motion, using an algorithm discussed below; it isnot converted to position data. In this embodiment, because the sensorsand strain gage are not in the head region, the head can be removableand replaceable, e.g., by threaded engagement with the handle (notshown), so that the sport device can continue to be used afterinstrument wear has occurred. Any desired type of removable head orcartridge can be used.

The unit 11 also includes a camera, which can be a 360 degree camera.Alternatively, the camera can be a 3D camera such as the Kinect cameraor the Intel RealSense camera for ease of generating 3D models and fordetecting distance of objects. To reduce image processing load, eachcamera has a high performance GPU to perform local processing, and theprocessed images, sound, and odor data are uploaded to a cloud storagefor subsequent analysis.

The unit 11 includes an electronic nose to detect odor. The electronicnose can simply be a MEMS device acting as a particle counter. Anembodiment of the electronic nose can be used that includes a fanmodule, a gas molecule sensor module, a control unit and an output unit.The fan module is used to pump air actively to the gas molecule sensormodule. The gas molecule sensor module detects the air pumped into bythe fan module. The gas molecule sensor module at least includes a gasmolecule sensor which is covered with a compound. The compound is usedto combine preset gas molecules. The control unit controls the fanmodule to suck air into the electronic nose device. Then the fan moduletransmits an air current to the gas molecule sensor module to generate adetected data. The output unit calculates the detected data to generatea calculation result and outputs an indicating signal to an operator orcompatible host computer according to the calculation result.

An electronic tongue sensor can be provided to sense quality of sweat orliquid. The tongue includes a liquid molecule sensor module, a controlunit and an output unit. Body liquid is applied or swiped on to theliquid molecule sensor module. The molecule sensor module detects theliquid molecules pumped into by the stirring module. The liquid moleculesensor module at least includes a molecule sensor which is covered witha compound. The compound is used to combine preset liquid molecules. Thecontrol unit controls the stirring module to pump liquid to be “tasted”into the electronic tongue device. Then the module transmits a flowcurrent to the liquid molecule sensor module to generate a detecteddata. The output unit calculates the detected data to generate acalculation result and outputs an indicating signal to an operator orcompatible host computer according to the calculation result. Suchelectronic tongue can detect quality of fog or liquid, among others.

In one embodiment for analyzing tooth structure, restorative materialswithin a tooth structure, and disease states of a tooth, the unit 11includes a probe 20 which may be attached to a variety of sport probes,and instruments to afford adaptability to a variety of situations inproviding diagnostic information on an object such as a naturallyoccurring structure, man-made materials placed or found within thestructure, diseased or otherwise affected, infected or effectedstructure, as well as structure that has been eroded, worn by attrition,abraded, abfracted, fractured, crazed, broken or otherwise compromisedthrough sport enthusiast use, misuse, fatigue or longevity of use. Theprobe 20 generates electrical outputs which are interpreted by a smartphone or computer.

In one embodiment, the probe 20 can be a vibratory transducer that sendsout vibrations at known frequency and amplitude. The probe 20 alsoincludes a receiver which can be an accelerometer, for example. Theaccelerometer is attached to the teeth and connected to a computer. Theaccelerometer digitizes the received vibrations and provides them intothe phone or computer. The transducer can be a single piezoelectrictransducer or an array with elements arranged to fit in a mouthpiece oran appliance to be worn over the oral arch. The transducer elements canbe mounted in silicone rubber or other material suitable for dampingmechanical coupling between the elements. Other materials may also beused for the array construction. For example, the transducer may beformed from one or more pieces of piezocomposite material, or anymaterial that converts electrical energy to acoustic energy. Thereceiver can also be positioned to fit in the mouthpiece or appliance.One embodiment of the receiver is an accelerometer, but a suitablepiezoelectric transducer can serve as the receiver as well.

The software in the computer compares these inputs to known vibrationresponses corresponding to striking states on a ball or sport object.The computer 30 displays a response on the computer screen for thatuser.

FIG. 1C schematically shows a method or app 2 which may be implementedby the computing unit 11 shown in FIG. 1B. For example, the app 2 may bea computer implemented method. A computer program may be provided forexecuting the app 2. The app 2 includes code for:

(21) capture user motion with accelerometer or gyroscope

(22) capture VR views through camera and process using GPU

(23) capture user emotion using facial recognition or GSR

(24) model user action using kinematic model

(25) compare user action with idea action

(26) coach user on improvement to user sport techniques.

As shown in FIG. 2A, a microcontroller 155 receives and processessignals from the sensor 112-114, and converts those signals into anappropriate digital electronic format. The microcontroller 155wirelessly transmits tension information in the appropriate digitalelectronic format, which may be encoded or encrypted for securecommunications, corresponding to the sensed traffic and/or crimeindication through a wireless communication module or transceiver 160and antenna 170. Optionally, a camera 140 can be provided to visuallydetect traffic and/or crime and movement of the structure. Whilemonitoring of the smart device 100 traffic and/or crime is continuous,transmission of tension information can be continuous, periodic orevent-driven, such as when the tension enters into a warning oremergency level. Typically the indicated tension enters a warning level,then an emergency level as tension drops below the optimal range, butcorresponding warning and emergency levels above the optimal range canalso be used if supported by the smart device 100. The microcontroller155 is programmed with the appropriate warning and emergency levels, aswell as internal damage diagnostics and self-recovery features.

The tension information can take any form, including a simplewarning/emergency indication that the tension is approaching orexceeding tension specifications, respectively. While under-tension isknown to be the primary cause of structural or mechanical problemsassociated with devices, over-tension can also be a problem and can alsobe reported by the smart device 100.

The sensors can detect force, load, tension and compression forces onthe device such as the device. Other data includes Acceleration;Velocity; Global absolute displacement; Local relative displacement;Rotation; Strain; Stress; Force; and Static-position video. Windspeed/direction; External temperature; weather parameters (rainfall,humidity, solar radiation, etc.); Internal or structural temperature;Mass loading (occupant count, etc.); Static tilt; Fatigue damage;Corrosion; Acoustic emission; and Moving-position video. A force issimply a push or pull to an object and can be detected by a load cell,pressure cell or strain sensor. A Load: Is simply a force applied to astructure. Ex: weight of vehicles or pedestrians, weight of wind pushingon sides. Tension & Compression are internal forces that make a memberlonger or shorter. Tension stretches a member and Compression pushes themember closer together. Acceleration can also be detected byForce-Balance (Servo) Piezoelectric Piezoresistive MEMS. Velocity can bemeasured by force-balance (servo) MEMS, or Mechanical Doppler Heatedwire. A local Displacement sensor can be LVDT/Cable potentiometerAcoustic Optical/laser Temperature Electrical Optical fiber. A rotationsensor can be Gyro MEMS Gyro Tilt Electro-mechanical MEMS. A strainsensor can be a resistance gauge Vibrating wire Optical fiber CorrosionElectrical Chemical sensors. A traffic and/or crime sensor can be amicrophone listening to acoustic emission, or Piezoelectric MEMS, forexample, and sonar sound processing can be used to detect where crimeactivity is coming from.

The sensor 112-114, transceiver 160/antenna 170, and microcontroller 155are powered by and suitable power source, which may optionally includean electromagnetic field (EMF) scavenging device 145, such as thoseknown in the art, that convert ambient EMF (such as that emitted byradio station broadcasts) into small amounts of electrical power. TheEMF scavenging device 145 includes a battery to buffer and store energyfor the microcontroller 155, sensor 112-114, camera 140 and wirelesscommunications 160/170, among others.

The circuit of FIG. 2A contains an analog front-end (“AFE”) transducer150 for interfacing signals from the sensor 112-114 to themicrocontroller 155. The AFE 150 electrically conditions the signalscoming from the sensor 112-114 prior to their conversion by themicrocontroller 155 so that the signals are electrically compatible withthe specified input ranges of the microcontroller 155. Themicrocontroller 155 can have a CPU, memory and peripheral circuitry. Themicrocontroller 155 is electrically coupled to a wireless communicationmodule 160 using either a standard or proprietary communicationstandard. Alternatively, the microcontroller 155 can include internallyany or all circuitry of the smart device 100, including the wirelesscommunication module 160. The microcontroller 155 preferably includespower savings or power management circuitry 145 and modes to reducepower consumption significantly when the microcontroller 155 is notactive or is less active. The microcontroller 155 may contain at leastone Analog-to-Digital Converter (ADC) channel for interfacing to the AFE150.

The battery/power management module 145 preferably includes theelectromagnetic field (EMF) scavenging device, but can alternatively runoff of previously stored electrical power from the battery alone. Thebattery/power management module 145 powers all the circuitry in thesmart device 100, including the camera 140, AFE 150, microcontroller155, wireless communication module 160, and antenna 170. Even though thesmart device 100 is preferably powered by continuously harvesting RFenergy, it is beneficial to minimize power consumption. To minimizepower consumption, the various tasks performed by the circuit should berepeated no more often than necessary under the circumstances.

Stress information from the smart device 100 and other information fromthe microcontroller 155 is preferably transmitted wirelessly through awireless communication module 160 and antenna 170. As stated above, thewireless communication component can use standard or proprietarycommunication protocols. Smart lids 100 can also communicate with eachother to relay information about the current status of the structure ormachine and the smart device 100 themselves. In each smart device 100,the transmission of this information may be scheduled to be transmittedperiodically. The smart lid 100 has a data storage medium (memory) tostore data and internal status information, such as power levels, whilethe communication component is in an OFF state between transmissionperiods. On the other hand, once the communication commences in the ONstate, the microcontroller 155 can execute the following tasks:

1. Neighbor discovery: in this task each smart device 100 sends a beaconidentifying its location, capabilities (e.g. residual energy), status.2. Cluster formation: cluster head will be elected based on the findingsin (1). The cluster children communicate directly with their clusterhead (CH). 3. Route discovery: this task interconnects the electedcluster heads together and finds the route towards the sink smart device(node) so that minimum energy is consumed. 4. Data transmission: themicrocontroller processes the collected color data and based on theadopted data dissemination approach, the smart device 100 will do one ofthe following. (a) Transmit the data as is without considering theprevious status; or (b) transmit the data considering the previousstatus. Here we can have several scenarios, which include: (i)transmitting the data if the change in reported tension exceeds thewarning or emergency levels; and (ii) otherwise, do not transmit.

The electronic of FIG. 2A operates with a big data discovery system ofFIG. 2B that determines events that may lead to failure. FIG. 2B is ablock diagram of an example stress monitoring system 200 that may beprocess the stress detected by the smart device 100 of FIG. 1, arrangedin accordance with at least some embodiments described herein. Alongwith the stress monitoring system 220, a first smart device such as asmart device 240, a second smart device 250, a third smart device 260, afourth smart device 280, and additional sensors 270 may also beassociated with the unit 200. The stress monitoring system 220 mayinclude, but is not limited to, a transceiver module 222, a stressdetection module 224, a stress prediction module 226, a determinationmodule 228, a stress response module 232, an interface module 234, aprocessor 236, and a memory 238.

The transceiver module 222 may be configured to receive a stress reportfrom each of the first, second, and third sport smart devices 240, 250,260. In some embodiments, the transceiver module 222 may be configuredto receive the stress reports over a wireless network. For example, thetransceiver module 222 and the first, second, and third smart devices240, 250, 260 may be connected over a wireless network using the IEEE802.11 or IEEE 802.15 standards, for example, among potentially otherstandards. Alternately or additionally, the transceiver module 222 andthe first, second, and third smart devices 240, 250, 260 may communicateby sending communications over conductors used to carry electricity tothe first, second, and third smart devices 240, 250, 260 and to otherelectrical devices in the unit 200. The transceiver module 222 may sendthe stress reports from the first, second, and third smart devices 240,250, 260 to the prediction module 226, the stress detection module 224,and/or the determination module 228.

The stress module 224 may be configured to detect stress on the sportobject as detected by the devices 100. The signal sent by the devices100 collectively may indicate the amount of stress being generatedand/or a prediction of the amount of stress that will be generated. Thestress detection module 224 may further be configured to detect a changein stress of non-smart devices associated with the unit 200.

The prediction module 226 may be configured to predict future stressbased on past stress history as detected, environmental conditions,forecasted stress loads, among other factors. In some embodiments, theprediction module 226 may predict future stress by building models ofusage and weight being transported. For example, the prediction module226 may build models using machine learning based on support vectormachines, artificial neural networks, or using other types of machinelearning. For example, stress may correlate with the load carried by abridge or an airplane structure. In other example, stress may correlatewith temperature cycling when a structure is exposed to constant changes(such as that of an airplane).

The prediction module 226 may gather data for building the model topredict stress from multiple sources. Some of these sources may include,the first, second, and third smart devices 240, 250, 260; the stressdetection module 224; networks, such as the World Wide Web; theinterface module 234; among other sources. For example, the first,second, and third smart devices 240, 250, 260 may send informationregarding human interactions with the first, second, and third smartdevices 240, 250, 260. The human interactions with the first, second,and third smart devices 240, 250, 260 may indicate a pattern of usagefor the first, second, and third smart devices 240, 250, 260 and/orother human behavior with respect to stress in the unit 200.

In some embodiments, the first, second, and third smart devices 240,250, 260 may perform predictions for their own stress based on historyand send their predicted stress in reports to the transceiver module222. The prediction module 226 may use the stress reports along with thedata of human interactions to predict stress for the system 200.Alternately or additionally, the prediction module 226 may makepredictions of stress for the first, second, and third smart devices240, 250, 260 based on data of human interactions and passed to thetransceiver module 222 from the first, second, and third smart devices240, 250, 260. A discussion of predicting stress for the first, second,and third smart devices 240, 250, 260 is provided below with respect toFIGS. 5 and 6.

The prediction module 224 may predict the stress for different amountsof time. For example, the prediction module 224 may predict stress ofthe system 200 for 1 hour, 2 hours, 12 hours, 1 day, or some otherperiod. The prediction module 224 may also update a prediction at a setinterval or when new data is available that changes the prediction. Theprediction module 224 may send the predicted stress of the system 200 tothe determination module 228. In some embodiments, the predicted stressof the system 200 may contain the entire stress of the system 200 andmay incorporate or be based on stress reports from the first, second,and third smart devices 240, 250, 260. In other embodiments, thepredicted stress of the system 200 may not incorporate or be based onthe stress reports from the first, second, and third smart devices 240,250, 260.

The determination module 228 may be configured to generate a unit stressreport for the system 200. The determination module 228 may use thecurrent stress of the system 200, the predicted stress of the system 200received from the prediction module 224; stress reports from the first,second, and/or third smart devices 240, 250, 260, whether incorporatedin the predicted stress of the system 200 or separate from the predictedstress of the system 200; and an amount of stress generated or thepredicted amount of stress, to generate a unit stress report.

In some embodiments, one or more of the stress reports from the first,second, and/or third smart device 240, 250, 260 may contain anindication of the current operational profile and not stress. In theseand other embodiments, the determination module 228 may be configured todetermine the stress of a smart device for which the stress reportindicates the current operational profile but not the stress. Thedetermination module 228 may include the determined amount of stress forthe smart device in the unit stress report. For example, both the firstand second smart device 240, 250 may send stress report. The stressreport from the first smart device 240 may indicate stress of the firstsmart device 240. The stress report from the second smart device 250 mayindicate the current operational profile but not the stress of thesecond smart device 250. Based on the current operational profile of thesecond smart device 250, the determination module 228 may calculate thestress of the second smart device 250. The determination module 228 maythen generate a unit stress report that contains the stress of both thefirst and second smart devices 240, 250.

In some embodiments, the stress monitoring system 220 may not includethe prediction module 226. In these and other embodiments, thedetermination module 228 may use stress reports from the first, second,and/or third smart devices 240, 250, 260, with the received amount ofstress inferred on non-smart devices, if any, to generate the unitstress report. The determination module 228 may send the unit stressreport to the transceiver module 222.

In some embodiments, the processor 236 may be configured to executecomputer instructions that cause the stress monitoring system 220 toperform the functions and operations described herein. The computerinstructions may be loaded into the memory 238 for execution by theprocessor 236 and/or data generated, received, or operated on duringperformance of the functions and operations described herein may be atleast temporarily stored in the memory 238.

Although the stress monitoring system 220 illustrates various discretecomponents, such as the prediction module 226 and the determinationmodule 228, various components may be divided into additionalcomponents, combined into fewer components, or eliminated, depending onthe desired implementation. In some embodiments, the unit 200 may beassociated with more or less smart devices than the three smart devices240, 250, 260 illustrated in FIG. 2.

FIG. 3 is a flow chart of an example method 300 of monitoring stress ofa sport or game unit, arranged in accordance with at least someembodiments described herein. The method 300 may be implemented, in someembodiments, by an stress monitoring system, such as the stressmonitoring system 220 of FIG. 2. For instance, the processor 236 of FIG.2B may be configured to execute computer instructions to performoperations for monitoring stress as represented by one or more of blocks302, 304, 306, 310, 312, and/or 314 of the method 300. Althoughillustrated as discrete blocks, various blocks may be divided intoadditional blocks, combined into fewer blocks, or eliminated, dependingon the desired implementation.

The method 300 may begin at one or more of blocks 302, 304, and/or 306.The blocks 302, 304, and/or 306 may occur at the same time or atdifferent times and may or may not depend on one another. Furthermore,one or more of the block 302, 304, 306 may occur during the method 300.For example, the method 300 may complete when blocks 304, 310, and 312occurs and without the occurrence of block 302 and 306.

In block 302, a change in stress of a device (device or beam) associatedwith a unit may be detected. A non-smart device may by any device thatreceives stress and does not generate an stress report indicating itsstress, for example a legacy racket without IoT electronics. A change inthe stress of a non-smart device may be detected using an stressdetection module and/or usage meter associated with the unit, such asthe stress detection module 224 and/or the smart device 100. Forexample, non-smart device stress can be estimated by the load the unitcarries, the temperature cycling experienced by the unit, for example.

After a change in stress of the non-smart device is detected, the method300 proceeds to block 310. In block 304, an stress report from a smartdevice such as the smart device 100 associated with the unit may bereceived. A smart device may be a device that detects stress andgenerates and transmits an stress report indicating the stress on thesmart device. The stress report may indicate predicted future stress ofthe smart device. In some embodiments, an stress report may be receivedat set intervals from the smart device regardless of a change in thestress report. Alternately or additionally, a stress report may bereceived after a change in the stress of the smart device results in achange to the stress report. After a stress report is received from thesmart device, the method 300 proceeds to block 310.

In block 306, stress experienced at the unit may be detected. Stress atthe unit may be detected using a stress detection module, such as thestress detection module 224 of FIG. 2B. After detecting stress at theunit, the method proceeds to block 310. At block 310, it is determinedif a change in the stress occurred. For example, if an increase instress occurs at the same time and at the same amount as an increase inthe stress of a non-smart device, a change in the stress may not occur.If a change in the stress occurs, the method 300 proceeds to block 312.If no change occurs, the method 300 ends.

At block 312, a unit stress report is generated for the unit. In someembodiments, the unit stress report may indicate the current stress ofthe unit. Alternately or additionally, the unit stress report mayindicate a current and predicted future stress of the unit. At block314, the unit stress report is transmitted to a maintenance provider. Insome embodiments, the unit stress report may be transmitted when theunit stress report indicates a change in stress for the unit that isgreater than a predetermined threshold. If the unit stress reportindicates a change in stress for the unit that is less than thepredetermined threshold, the unit stress report may not be transmittedto the provider of maintenance services.

FIG. 5 shows in more details the computer 30 and the interface to theprobe 20. An amplifier 90 amplifies vibratory output from a transducer92. A pick up unit having an accelerometer (or an array) 96 receivesreflected vibrations from user arm or leg 94, among others. A computer98 includes a digital converter to digitize output from the pick-up unitand software on the computer 98 can process the captured diagnosticdata. Diagnostic software 100 can include a database of knownrestorations, diseases, and tissue conditions whose signatures can bematched against the capture diagnostic data, and the result can bedisplayed on a screen for review by the athlete.

Included in one embodiment of the instrumentation is the transmitter ortransducer, which will emit the vibrations that will be imparted to theteeth and jaws. This will be connected to a power supply and amplifier,which will allow for a frequency range. On electrical excitation, thetransducer emits an outgoing vibration. That vibration will then travelinto the arm or leg and down is root into the soft tissues and out intothe bones or jaws. The accelerometer or detector will be placed on thebone of interest. It will receive the vibrations from the emitter. Theeffect of the vibrations on the muscle of interest will generate apattern of frequency vibrations. Those vibrations will be digitallyconverted and analyzed against known dental states in the software ofthe computer. As the data is collected various linear samplings andcomparisons will be made against the database. Software will make thesecomparisons as the data is received from the teeth.

FIG. 5 schematically shows a method or app 52 to perform collaborativeVR/AR gaming. The app 52 includes code for:

(51) capture 360 degree view of the live event

(52) detect head position of the viewer

(53) adjust viewing angle on screen based on head position and userposture

(54) render view to simulate action based on user control rather thanwhat the professional is doing

(55) augment view with a simulated object that is powered by vieweraction as detected by sensors on viewer body

(56) compare professional result with simulated result and show resultto a crowd of enthusiasts for social discussion.

FIG. 6 is a flowchart of a method of an embodiment of the presentdisclosure. Referring to FIG. 6, a smart system may collect from smartdevices state change events of a smart system in operation 601. That is,the smart system of FIG. 4 collects information on each of the group ofdevices, the smart devices, the smart appliances, the security devices,the lighting devices, the energy devices, and the like. The state changeevents indicate when there is a change in the state of the device or thesurrounding environment. The state change events are stored by the smartsystem. In operation 603, the system may determine whether a series ofthe collected state change events are a known pattern. That is, thegateway determines whether there are events which have been correlatedor identified in the past. If the collected state change events havebeen identified in the past, it may be necessary to determine that thesmart systems trusts the identification the collected state changeevents. The trust factor of the identification of the collected statechange events may be determined by the number of users who haveidentified the collected state change events or the number of timecollected state change events have been repeated and identified. Inoperation 605, when the series of the collected state change events isan unknown pattern, request users of the smart system to identify whatcaused the collected state change events request. That is, the systemtransmits to a gamification application (hereinafter app) on the user'smobile device a request to identify the collected state change events.The gamification app displays the information and request the user enterinformation identifying the collected state change events. Each of themobile devices transmits this information back to the system to thegamification module. In operation 605, the system transmits the eachuser's identified collected state change events to the other user's ofthe smart home system and they each vote on the best identification ofthe collected state change events. Thus, the identified collected changestate events that have been repeatedly identified over a period of weeksincreases, the trustworthiness of the identification increases.Likewise, if every user of the smart system makes the sameidentification of the collected change state events, the identifiedcollected change state events may be considered trustworthy at point.Such a determination of a threshold for when the identified collectedchange state events are considered trustworthy and therefore need not berepeated, is made by a system administrator. However, it will beunderstood that such a trustworthiness of this type only gives higherconfidence of this particular dataset at that point in time. As suchfurther repetition is required, since the sensor data may have noise,the more datasets to be identified to the pattern, the more robust thetrustworthiness will be. Until the robustness reaches a threshold, thenthe system can confirm this is a known trustworthy pattern.

The system can use gaming to help sport enthusiasts improve dental careor maintain teeth hygiene. This may involve use of virtual tools,corresponding to such tools used in normal dental hygiene: sport device,tooth picks, dental floss, gum massaging aids, etc. In this embodiment,the game may, for example, have the object of fighting tooth or gumdecay, damage or infection which may be caused by carries or otherinfectious agents. The user is presented with a library of tools and hasto select a tool to treat a certain developing virtual condition, e.g.carries or a gum infection. The game rules determine a certaincontinuous progress of infection which if not properly “treated” by theuser will cause decay of one or more teeth, gum infection, potentialbleeding, loss of teeth, etc. In step 13, the user may score pointsdepending on his ability to choose the right tools to treat a particularcondition or in avoiding a condition from developing. Next, it isdetermined whether the condition of the teeth is satisfactory. If yes,the process terminates. If no, then the user is prompted whether hewishes to select another tool. If no, the process terminates. If yes,the process restarts. Here again, the game, in addition to being amusingand providing an insight of the user into his own teeth, may beeducational, particularly for children, on teeth oral hygiene methodsand on the importance of maintaining oral hygiene.

In accordance with another embodiment of the invention the game mayinvolve use of a variety of virtual imaginary tools such as virtualguns, wands, etc. in order to fight infectious agents of the teeth orgums.

Smart Sport Glove

FIG. 7 shows an exemplary glove which can be thin to provide touchsensitivity or thick to provide shock protection for boxers. A body 12of the boxing glove 10 includes an impact measuring device 14 isembedded within the glove 12 in an area protected from direct impact.Such an area includes the cuff 15 of the glove 12 or that portion of theglove 12 adjacent a user's palm, or adjacent an inside surface of auser's fingers. Placement of the impact measuring device 14 into thelining of the glove in such an area allows for the force of a blow to bemeasured without presenting a hazard to the recipient of the blow. Underthe embodiment, an impact measuring device 14 would be included in theright glove 12 for a right handed fighter, or the left glove 12 for aleft handed fighter. For fighters that are equally effective with bothhands, or to improve monitoring accuracy, an impact measuring device 14would be included in both gloves 12. The impact measuring system 20. Theimpact measuring system 20 includes an impact measuring device 14 andimpact display unit 16. The impact measuring device 14 is linked to theimpact display 28 via a radio frequency (rf) link 32. Under theembodiment, the impact measuring device 14 includes at least one 3-axisaccelerometer. A thin version of the glove can be worn to detect a golfstroke or a tennis stroke with legacy clubs or rackets that lacks IoTintelligence.

1. A Glove Comprising:

a glove body;

a processor in the glove body and coupled to a wireless transceiver;

a camera coupled to the glove body;

a sensor disposed in the glove body; and

an accelerometer disposed within the glove body to detect accelerationof the glove.

2. The glove of claim 1, at least one sensor selected from a sensor setcomprising: a pressure sensor configured to detect at least one pressureevent at a glove body external surface location; a glove motion sensorconfigured to detect at least one motion event of the glove; a digitmotion sensor configured to detect at least one motion event of at leastone digit of the user; a temperature sensor configured to detect atemperature at a glove body external surface location; and a contactsensor configured to detect a contact event of the glove with a contactobject.

3. The glove of claim 1, the sensor comprising at least one of the sameas the second sensor or different than the second sensor, the handexercise event at least one of the same as the second hand exerciseevent or different than the second hand exercise event.

4. The glove of claim 1, the hand exercise regimen selected from a handexercise regimen set comprising at least one of: a physical therapy handexercise regimen; a physical training hand exercise regimen; or aphysical performance hand exercise regimen.

5. The glove of claim 1, the glove comprising a gesture identifyingcomponent configured to identify at least one hand gesture detected byat least one sensor; the memory configured to, upon receiving anindication of a hand gesture identified by the gesture identifyingcomponent, store data corresponding to the hand gesture in the memory;and the device interface configured to, upon connecting to the device,provide at least some of the stored data corresponding to the handgesture to the device.

6. The glove of claim 1, the glove comprising a plurality of fingerreceptacles, each having a sensor.

7. The glove of claim 1, comprising a sensor worn by an opponent inwireless communication with the processor to communicate the force of animpact from the glove.

8. A system for measuring a force of impact of a boxing glove of a boxercomprising:

an accelerometer disposed in the boxing glove of the boxer for measuringthe force of impact of the boxing glove on an opponent;

a radio frequency transmitter disposed in the boxing glove and coupledto the accelerometer for transmitting impact measurements;

a radio frequency receiver for receiving the impact measurements; and

a display coupled to the radio frequency receiver for displaying themeasured impacts.

Smart Sport Band

FIG. 8 shows an exemplary stick on wearable monitoring device for sportsand fitness applications. The wireless sensor electronics 14 is mountedon a band-aid in the example of FIG. 8. The band-aid can be removed uponcompletion of the sports event. The central patch can be recycled, andthe adhesive portion can be disposed. While the embodiment is shown as aband-aid, the inventors contemplate that any suitable bands, straps,attachments can be used in lieu of the band-aid to attach the sensors tothe body. For example, in Virtual Reality (VR) sports applications,sensors including gyroscopes and cameras can be positioned on variousbody portions to capture motion as well as eye tracking, mouth tracking,speech recognition, among others.

One embodiment uses Samsung's Bio-Processor which is an all-in-onehealth solution chip. By integrating not only Analog Front Ends (AFE),but also microcontroller unit (MCU), power management integrated circuit(PMIC), digital signal processor (DSP), and eFlash memory, it is able toprocess the bio-signals it measures without the need of externalprocessing parts. Even with its integrated design, the Bio-Processor isparticularly innovative thanks to its incredibly small size. Whencompared to the total area of the discrete parts, the Bio-Processor isonly about one fourth of the total combined size, which is ideal forsmall wearable devices, offering a bounty of options when designing newdevices. The Bio-Processor has five AFEs including bioelectricalimpedance analysis (BIA), photoplethysmogram (PPG), electrocardiogram(ECG), skin temperature, and galvanic skin response (GSR) into a singlechip solution that measures body fat, and skeletal muscle mass, heartrate, heart rhythm, skin temperature and stress level, respectively.

One embodiment provides a flexible and stretchable electronic patch thatmonitors impact or other events whereby a flexible substrate isgeometrically patterned to allow the substrate to undergo substantialstretching and flexing while large regions of the substrate materialexperiences local strains much lower than the macroscopic appliedstrain. The geometric patterning of the substrate facilitates continuouslow strain domains (LSDs) throughout the substrate—where low straindomains are defined as regions that experience strain levels (magnitude)lower than the macroscopic applied strain. Conventional electroniccomponents can be mounted to the LSDs, and conventional metal traces canbe routed through the LSDs, dramatically reducing the stressestransmitted to the components and traces by the substrate duringstretching and flexing, and therefore reducing the potential forcomponent debonding, trace cracking, and circuit failure. Thegeometrically patterned strain relief features (SRFs) are dispersedeither regularly or irregularly throughout the substrate. Thegeometrically patterned SRF regions form “hinge-like” domains. Duringmacroscopic deformation, the SRFs rotate, translate, open, close, orotherwise change shape, causing the “hinge-like” regions to deform, andthe remaining larger LSD substrate regions to primarily rotate andtranslate. The SRFs are designed such that the “hinge-like” regions alsoexhibit relatively small strain compared to the macroscopic appliedstrain and thus enable conductive traces, such as copper or gold, to runthrough the hinges and maintain function during stretching, flexing andtwisting of the patch. The substrate can be multilayered to enablerunning conductive traces, ground layers, vias, and/or components on/inmultiple layers through the thickness of the overall substrate. Thegeometric patterning can be designed to enable different stretching,flexing and twisting, providing uniaxial, biaxial, and multi-axialstretchability or flexibility, and the ability to conform to a varietyof surface curvatures. The geometrically patterned substrate offers ameans of packaging complex multi-layered electronics designs formonitoring impact (and other) events onto a stretchable and flexiblesubstrate enabling the device to dynamically stretch, bend, twist, andconform to arbitrary shapes. The stretchable, flexible geometricallystructure electronics can be fabricated using the same technologies forconventional flexible circuit boards where the stretch-enablingpatterning can be imparted at different stages in the fabricationprocess and can also be fabricated using emerging materials andfabrication methods. The Stretchable bandaid has the stretchable,flexible substrate described above with multiple LSDs for placement ofelectronic components (e.g., accelerometers, gyroscopes, pressuretemperature, gas and fluid sensors, microprocessors, transceivers, GPS,clocks, actuators, vias, and batteries (or other energy source)) andmultiple patterned hinge-like regions bridging the LSDs which enable therouting of conducting interconnecting traces. The SEHIM patch can takethe form factor of a bandaid or bandage or other such wearable formfactor. The geometric patterning provides stretch, flex and twist toconform to a body and stretch, flex and twist to move or deform with abody. The bandaid detects impact accelerations, using a 3-axisaccelerometer and processes the raw acceleration data in themicroprocessor. The processed data is stored in the microprocessor andlater (or potentially in real time) transmitted via the Bluetooth to asmart phone, tablet or computer. This embodiment encompasses wirelesscommunication but wired communication may be desirable in someapplications and can be accommodated by this invention. The bandaid canbe stretched, bent and twisted with the traces and components at lowstrains to maintain electrical function. In all cases there waseffectively no strain on the components and solder joints. The bandaidcan also possess an adhesive backing for direct adhesion to the head,body or object. The band can also be coated to provide both addedcomfort and protection against moisture, water, and other environmentalfactors. The band can also contain other sensors including gyroscopes,temperature and pressure sensors, moisture sensors, clocks, chemicaland/or biological sensors, etc. Features of the smart band can include:

1. A smart patch, comprising:

a band to be placed over a body portion;

a processor in the band and coupled to a wireless transceiver;

a camera coupled to the band;

a sensor disposed in the band; and

an accelerometer disposed within the band to detect acceleration of theband.

2. The patch of claim 1, comprising a plurality of smart patches forminga mesh network and communicating episodically to conserve power.

3. The patch of claim 1 where the electronic components, sensors, andinterconnects of the patch monitor, record, process and/or transmitevents of interest (such as accelerometers and gyroscopes for impactevents, temperature sensors for temperature and/or temperaturegradients, pressure sensors, moisture sensors, chemical sensors).

4. The patch of claim 1 comprised for sensing and/or monitoring impactevents where the sensors are accelerometers, gyroscopes, and/or pressuresensors.

5. The patch of claim 1 comprised for sensing and/or monitoring and/orcontrolling ongoing events where the sensors monitor temperature,temperature gradients, motion, position, environmental or chemicallevels, or other such information.

6. The patch of claim 1 comprised for sensing events or otherinformation including mounting multiple distributed sensors forobtaining spatial and/or temporal distribution in the data and/ormultiple sensors sensing different information and data.

7. The patch of claim 1 including wired or wireless communication, suchas a Bluetooth module or a wi-fi module or other transmission module,transmitting and/or receiving information to/from another device.

8. The patch of claim 1 with power and energy sources includingbatteries, wired or wireless rechargeable batteries, photovoltaics,thermoelectrics, or energy harvesters.

9. The patch of claim 1 with an adhesive backing for directly adheringto a head, a body, or an object.

10. The patch of claim 1 contained in an adhesive or a sleeve foradhering or attaching to a head, a body, or an object.

11. The patch of claim 1 coated with a coating for protection againstthe elements (water, moisture, dirt, other) and/or for increased comfortto the wearer.

12. The patch of claim 1, comprising a geometrically patterned substratethat contains regions of low strain domains (LSDs) bridged by hingeablestrain relief features (SRFs) which also contain low strain regions andenable the stretching, flexing and twisting of the patch whilemaintaining continuous low strain regions for mounting electroniccomponents and routing traces.

13. The patch of claim 1 for attachment to or on or an object, orembedded in an object.

14. The patch of claim 1 in the form factor of a rectangular or a squareor a triangular or other polygon or circular or elliptical or othergeometric shape bandage.

15. The patch of claim 1 in the form factor that is or contains anycombination of rectangles, triangles, circles, ellipses or other formfactors.

16. The patch of claim 1 with different geometric patterning ofdifferent numbers and shapes and orientations of low strain domains,different numbers and orientation of geometrically structured hinge-likedomains, and different geometries of hinge-like domains.

17. The patch of claim 1 as a programmable circuit board for arbitraryapplications.

18. The patch of claim 1 fabricated using current flex circuitmanufacturing methods and materials.

19. The patch of claim 1 comprising a cloud storage to receive sensordata.

20. The patch of claim 1 where the polymer layers are current flexmanufacturing polymers such as Kapton, polyimides, polyamides,polyesters, or other as well as elastomers such as silicone rubbers(PDMS) or polyurethanes or other elastomers and the interconnects aremetals that have high electrical conductivity, such as copper or gold,or where the interconnects are emerging stretchable electronic materialsand stretchable conductive inks and materials.

Smart Clothing

FIG. 9 shows an exemplary shirt based embodiment where sensors can bepositioned anywhere on the shirt and when worn, can capture position,video, and vital signs. One embodiment uses Samsung's Bio-Processor toprocess the bio-signals it measures without the need of externalprocessing parts with five AFEs including bioelectrical impedanceanalysis (BIA), photoplethysmogram (PPG), electrocardiogram (ECG), skintemperature, and galvanic skin response (GSR) into a single chipsolution that measures body fat, and skeletal muscle mass, heart rate,heart rhythm, skin temperature and stress level, respectively. Featuresof the smart clothe can include:

1. A smart clothing, comprising:

-   -   a shirt, underwear, pant or sock;    -   a band to be secured to the a shirt, underwear, pant or sock;    -   a processor in the band and coupled to a wireless transceiver;

an EKG amplifier coupled to the band;

a sensor disposed in the band; and

an accelerometer disposed within the band to detect acceleration of theband.

2. The clothing of claim 1, comprising a plurality of bands forming amesh network and communicating episodically to conserve power.

3. The clothing of claim 1 where the electronic components, sensors, andinterconnects of the patch monitor, record, process and/or transmitevents of interest (such as accelerometers and gyroscopes for impactevents, temperature sensors for temperature and/or temperaturegradients, pressure sensors, moisture sensors, chemical sensors).

4. The clothing of claim 1 comprised for sensing and/or monitoringimpact events where the sensors are accelerometers, gyroscopes, and/orpressure sensors.

5. The clothing of claim 1 comprised for sensing and/or monitoringand/or controlling ongoing events where the sensors monitor temperature,temperature gradients, motion, position, environmental or chemicallevels, or other such information.

6. The clothing of claim 1 comprised for sensing events or otherinformation including mounting multiple distributed sensors forobtaining spatial and/or temporal distribution in the data and/ormultiple sensors sensing different information and data.

7. The clothing of claim 1 including wired or wireless communication,such as a Bluetooth module or a wi-fi module or other transmissionmodule, transmitting and/or receiving information to/from anotherdevice.

8. The clothing of claim 1 with power and energy sources includingbatteries, wired or wireless rechargeable batteries, photovoltaics,thermoelectrics, or energy harvesters.

9. The clothing of claim 1 with an adhesive backing for directlyadhering to a head, a body, or an object.

10. The clothing of claim 1 contained in an adhesive or a sleeve foradhering or attaching to a head, a body, or an object.

11. The clothing of claim 1 coated with a coating for protection againstthe elements (water, moisture, dirt, other) and/or for increased comfortto the wearer.

12. The clothing of claim 1, comprising a geometrically patternedsubstrate that contains regions of low strain domains (LSDs) bridged byhingeable strain relief features (SRFs) which also contain low strainregions and enable the stretching, flexing and twisting of the patchwhile maintaining continuous low strain regions for mounting electroniccomponents and routing traces.

13. The clothing of claim 1 for attachment to or on or an object, orembedded in an object.

14. The clothing of claim 1 in the form factor of a rectangular or asquare or a triangular or other polygon or circular or elliptical orother geometric shape bandage.

15. The clothing of claim 1 in the form factor that is or contains anycombination of rectangles, triangles, circles, ellipses or other formfactors.

16. The clothing of claim 1 with different geometric patterning ofdifferent numbers and shapes and orientations of low strain domains,different numbers and orientation of geometrically structured hinge-likedomains, and different geometries of hinge-like domains.

17. The clothing of claim 1 as a programmable circuit board forarbitrary applications.

18. The clothing of claim 1 fabricated using current flex circuitmanufacturing methods and materials.

19. The clothing of claim 1 comprising a cloud storage to receive sensordata.

20. The clothing of claim 1 where the polymer layers are current flexmanufacturing polymers such as Kapton, polyimides, polyamides,polyesters, or other as well as elastomers such as silicone rubbers(PDMS) or polyurethanes or other elastomers and the interconnects aremetals that have high electrical conductivity, such as copper or gold,or where the interconnects are emerging stretchable electronic materialsand stretchable conductive inks and materials.

Smart Handle

FIGS. 11A-11B show an exemplary smart handle for sports such as tennis,badminton, table tennis, and golf, among others. The wireless sensorelectronics 14 is mounted on a handle in the example of FIG. 11B. Thehandle can be embedded or can be removed upon completion of the sportsevent. The sports event does not have to be real, for example, inVirtual Reality (VR) sports applications, sensors including gyroscopesand cameras can be positioned on various body portions to capture motionas well as eye tracking, mouth tracking, speech recognition, amongothers.

The handle includes a swing analyzer measurement portion 54 in the gripend 52 of the handle of a golf club or a tennis/badminton racket, and aremote or handheld unit 56. The swing analyzer measurement portion 54includes an accelerometer 16 of combination accelerometer and gyroscopeor magnetometer unit, a processor unit 58 coupled to the accelerometer16, and a battery 20 that is electrically coupled to and provides powerto the accelerometer 16 and processor unit 58. A camera is included tocapture videos of the swing and also the game in progress for futurereference. A communications unit 60 is also housed in the grip end 52 ofthe golf club 50, receives power from the battery 20, and is coupled tothe processor unit 58. Swing analyzer measurement portion 54, with orwithout the communications unit 60, may be assembled as an integral unitand inserted into a hollow portion of the handle of the golf club ortennis/racket handle 50 at the grip end 52 thereof. Processor unit 58may be an integrated device that includes hardware and softwarecomponents capable of processing acceleration measured by theaccelerometer(s) 16 and converting the measured acceleration into dataabout the force on the shaft and position of the face of the club atimpact at a set distance. If the measured force exceeds a threshold themeasured force or a signal derived therefrom is transmitted via thecommunications unit 60 to the handheld unit 56. If not, acceleration andface position at impact of the golf club or tennis racket handle 50 isobtained again. The threshold is set so that only acceleration or forcemeasurements arising from actual swings of the golf club 50 aretransmitted to the handheld unit 56. Handheld or remote unit 56 includesan application or computer program embodied on a non-transitorycomputer-readable medium that performs the golf ball carrying distanceestimation or prediction steps, as well as manages the training stagedescribed above. Importantly, the handheld unit 56 receives accelerationmeasurement data from the golf clubs/tennis rackets equipped with aswing analyzer measurement portion 54 and the club face angle inrelation to the swing plane, and manages the carrying distanceestimation steps for all golf clubs equipped with the swing analyzermeasurement portion 54 that are designed to communicate therewith.Handheld or remote unit 56 may be a standalone unit for use only withthe golf clubs equipped with the swing analyzer measurement portion 54,and incorporating the application thereon, or may be a smartphone orsimilar device with the application embodied thereon or downloadedthereto and that can be used for other purposes. Handheld or remote unit56 includes a communications unit 70 that communicates with thecommunications unit 60 on each golf club or tennis racket handle 50,i.e., with the communications units present on all of the golf clubs 50equipped with swing analyzer measurement portions 54 and which have beendesignated to communicate therewith. Communications unit 70 may be anintegral part of the handheld unit 56 as is the case when the handheldunit 56 is a smartphone. Communications unit 70 may also communicatewith another device such as a Smartphone, to perform more datamanipulations relating to the golf swing and/or swing results to providemore information to the user. The data and the calculation/manipulationresults can be stored in the Smartphone and displayed when desired.Currently usable Smartphones are Apple iOS iPhones and Android operatingsystem phones. Handheld or remote unit 56 also includes a processor unit72, a storage unit 74 and a display 76. When the handheld unit 56 is asmartphone or similar device, all of the processor unit 72, storage unit74 and display 76 may be integral components thereof. Processor unit 72performs functions similar to those performed by the processor unit 18described above, e.g., calculates an estimated carrying distance for thegolf ball based on the acceleration measured by the accelerometer(s) 16and transmitted via the communications units 60, 70, and the type ofclub provided to the application or computer program in the processorunit 72. Storage unit 74 receives and stores information about thecarrying distance of each club as a function of clock or swing position,e.g., in the form of a virtual table associating the type of club, theswing or swing position and the estimated carrying distance.

Other sensors can be used as well. For example, the handle can containconductive ink to capture biometric. One embodiment uses Samsung'sBio-Processor which is an all-in-one health solution chip to measurebioelectrical impedance analysis (BIA), photoplethysmogram (PPG),electrocardiogram (ECG), skin temperature, and galvanic skin response(GSR) into a single chip solution that measures body fat, and skeletalmuscle mass, heart rate, heart rhythm, skin temperature and stresslevel, respectively. The handle can also contain other sensors includinggyroscopes, temperature and pressure sensors, moisture sensors, clocks,chemical and/or biological sensors, etc. Features of the smart handlecan include:

1. A smart handle, comprising:

a handle;

a processor in the band and coupled to a wireless transceiver;

a camera coupled to the handle;

a sensor disposed in the handle; and

an accelerometer disposed within the band to detect acceleration of thehandle.

2. The handle of claim 1, comprising a plurality of smart handlesforming a mesh network and communicating episodically to conserve power.

3. The handle of claim 1 where the electronic components, sensors, andinterconnects of the handle monitor, record, process and/or transmitevents of interest (such as accelerometers and gyroscopes for impactevents, temperature sensors for temperature and/or temperaturegradients, pressure sensors, moisture sensors, chemical sensors).

4. The handle of claim 1 comprised for sensing and/or monitoring impactevents where the sensors are accelerometers, gyroscopes, and/or pressuresensors.

5. The handle of claim 1 comprised for sensing and/or monitoring and/orcontrolling ongoing events where the sensors monitor temperature,temperature gradients, motion, position, environmental or chemicallevels, or other such information.

6. The handle of claim 1 comprised for sensing events or otherinformation including mounting multiple distributed sensors forobtaining spatial and/or temporal distribution in the data and/ormultiple sensors sensing different information and data.

7. The handle of claim 1 including wired or wireless communication, suchas a Bluetooth module or a wi-fi module or other transmission module,transmitting and/or receiving information to/from another device.

8. The handle of claim 1 with power and energy sources includingbatteries, wired or wireless rechargeable batteries, photovoltaics,thermoelectrics, or energy harvesters.

9. The handle of claim 1 with an adhesive backing for directly adheringto a head, a body, or an object.

10. The handle of claim 1 contained in an adhesive or a sleeve foradhering or attaching to a head, a body, or an object.

11. The handle of claim 1 coated with a coating for protection againstthe elements (water, moisture, dirt, other) and/or for increased comfortto the wearer.

12. The handle of claim 1, comprising a geometrically patternedsubstrate that contains regions of low strain domains (LSDs) bridged byhingeable strain relief features (SRFs) which also contain low strainregions and enable the stretching, flexing and twisting of the handlewhile maintaining continuous low strain regions for mounting electroniccomponents and routing traces.

13. The handle of claim 1 for attachment to or on or an object, orembedded in an object.

14. The handle of claim 1 in the form factor of a rectangular or asquare or a triangular or other polygon or circular or elliptical orother geometric shape bandage.

15. The handle of claim 1 in the form factor that is or contains anycombination of rectangles, triangles, circles, ellipses or other formfactors.

16. The handle of claim 1 with different geometric patterning ofdifferent numbers and shapes and orientations of low strain domains,different numbers and orientation of geometrically structured hinge-likedomains, and different geometries of hinge-like domains.

17. The handle of claim 1 as a programmable circuit board for arbitraryapplications.

18. The handle of claim 1 fabricated using current flex circuitmanufacturing methods and materials.

19. The handle of claim 1 comprising a cloud storage to receive sensordata.

20. The handle of claim 1 where the polymer layers are current flexmanufacturing polymers such as Kapton, polyimides, polyamides,polyesters, or other as well as elastomers such as silicone rubbers(PDMS) or polyurethanes or other elastomers and the interconnects aremetals that have high electrical conductivity, such as copper or gold,or where the interconnects are emerging stretchable electronic materialsand stretchable conductive inks and materials.

Smart Protective Gear

FIGS. 12A-12C illustrate smart protective gears embedded with the IoTsensors and instrumentations to report potential health issues. Forsoccer, the protection includes shin guards. For football, theprotection includes Helmets, Chin Straps & Chin Shields, Cups & AthleticSupporters, Elbow Sleeves & Arm Pads, Back Plates & Rib Protection,Facemasks, Girdles, Helmet Visors, Shoulder Pads, Hip & Tail Pads,Mouthguards, Neck Rolls. For motorcycling, the protection includeshelmet, should pads, jacket with back protection, padded gloves, leatherpants, knee pads, and boots. For rock climbing, the protection includesshoes, carabiners, webbing, harnesses, among others.

The wireless sensor electronics 14 is mounted on the helmet or shoulderpad in the example of FIG. 12A or 12C. The electronics 14 can beembedded or can be removed upon completion of the sports event. Thesports event does not have to be real, for example, in Virtual Reality(VR) sports applications, sensors including gyroscopes and cameras canbe positioned on various body portions to capture motion as well as eyetracking, mouth tracking, speech recognition, among others.

The protection gear includes an impact sensor such as an accelerometerto indicate if concussion has occurred. Other sensors can be used aswell. For example, the handle can contain conductive ink to capturebiometric. One embodiment uses Samsung's Bio-Processor which is anall-in-one health solution chip to measure bioelectrical impedanceanalysis (BIA), photoplethysmogram (PPG), electrocardiogram (ECG), skintemperature, and galvanic skin response (GSR) into a single chipsolution that measures body fat, and skeletal muscle mass, heart rate,heart rhythm, skin temperature and stress level, respectively. Thehandle can also contain other sensors including gyroscopes, temperatureand pressure sensors, moisture sensors, clocks, chemical and/orbiological sensors, etc.

Impact sensors, or accelerometers, measure in real time the force andeven the number of impacts that players sustain. Data collected is sentwirelessly via Bluetooth to a dedicated monitor on the sidelines, whilethe impact prompts a visual light or audio alert to signal players,coaches, officials, and the training or medical staff of the team. Onesuch sensor example is the ADXL377 from Analog Devices, a small, thinand low-power 3-axis accelerometer that measures acceleration frommotion, shock, or vibration. It features a full-scale range of ±200 g,which would encompass the full range of impact acceleration in sports,which typically does not exceed 150 g's. Specifically designed forconcussion and head-trauma detection, at 3 mm×3 mm×1.45 mm, the deviceis small enough to be designed into a helmet. Sensitivity, listed at 6.5mV/g with −3 dB bandwidth at 1.6 kHz, is sufficiently high for theapplication. When a post-impact player is removed from a game and notallowed to return until cleared by a concussion-savvy healthcareprofessional, most will recover quickly. If the injury is undetected,however, and an athlete continues playing, concussion recovery oftentakes much longer. In addition, the industry is finding that long-termproblems from delayed or unidentified injury can include: Earlydementia, Depression, Rapid brain aging, and Death. The cumulativeeffects of repetitive head impacts (RHI) increases the risk of long-termneuro-degenerative diseases, such as Parkinson's disease, Alzheimer's,Mild Cognitive Impairment, and ALS or Lou Gehrig's disease. The sensors'most important role is to alert to dangerous concussions. Yet, the actof real-time monitoring brings these players to the attention of theircoaches not only to monitor serious impacts but, based on the dataprovided by the sensors, also help to modify a player's technique sothat they are not, for example, keeping their head low where they cansustain injury to the front and top of the skull. In the NFL there alsohas been an aggressive crackdown against hits to the head and neck—aresponse to the ongoing concussion crisis—resulting in immediate penaltyto players using their helmets as a “weapon”. Customized mouthguardsalso have sensors therein. A customized mouthguard has tested to be 99percent accurate in predicting serious brain injury afternear-concussive force, according to an Academy of General Dentistrystudy2. Teeth absorb and scatter infrared light, which shows how muchforce is taking place at the moment of impact.

Features of the smart protective gear can include:

1. A smart protection gear, comprising:

-   -   a wearable surface;    -   a processor in the band and coupled to a wireless transceiver;    -   a camera coupled to the surface;    -   a sensor disposed in the surface; and    -   an accelerometer disposed within the band to detect acceleration        of the surface.

2. The protection gear of claim 1, comprising a plurality of smartprotection gears forming a mesh network and communicating episodicallyto conserve power.

3. The protection gear of claim 1 where the electronic components,sensors, and interconnects of the protection gear monitor, record,process and/or transmit events of interest (such as accelerometers andgyroscopes for impact events, temperature sensors for temperature and/ortemperature gradients, pressure sensors, moisture sensors, chemicalsensors).

4. The protection gear of claim 1 comprised for sensing and/ormonitoring impact events where the sensors are accelerometers,gyroscopes, and/or pressure sensors.

5. The protection gear of claim 1 comprised for sensing and/ormonitoring and/or controlling ongoing events where the sensors monitortemperature, temperature gradients, motion, position, environmental orchemical levels, or other such information.

6. The protection gear of claim 1 comprised for sensing events or otherinformation including mounting multiple distributed sensors forobtaining spatial and/or temporal distribution in the data and/ormultiple sensors sensing different information and data.

7. The protection gear of claim 1 including wired or wirelesscommunication, such as a Bluetooth module or a wi-fi module or othertransmission module, transmitting and/or receiving information to/fromanother device.

8. The protection gear of claim 1 with power and energy sourcesincluding batteries, wired or wireless rechargeable batteries,photovoltaics, thermoelectrics, or energy harvesters.

9. The protection gear of claim 1 with an adhesive backing for directlyadhering to a head, a body, or an object.

10. The protection gear of claim 1 contained in an adhesive or a sleevefor adhering or attaching to a head, a body, or an object.

11. The protection gear of claim 1 coated with a coating for protectionagainst the elements (water, moisture, dirt, other) and/or for increasedcomfort to the wearer.

12. The protection gear of claim 1, comprising a geometrically patternedsubstrate that contains regions of low strain domains (LSDs) bridged byhingeable strain relief features (SRFs) which also contain low strainregions and enable the stretching, flexing and twisting of theprotection gear while maintaining continuous low strain regions formounting electronic components and routing traces.

13. The protection gear of claim 1 for attachment to or on or an object,or embedded in an object.

14. The protection gear of claim 1 in the form factor of a rectangularor a square or a triangular or other polygon or circular or ellipticalor other geometric shape bandage.

15. The protection gear of claim 1 in the form factor that is orcontains any combination of rectangles, triangles, circles, ellipses orother form factors.

16. The protection gear of claim 1 with different geometric patterningof different numbers and shapes and orientations of low strain domains,different numbers and orientation of geometrically structured hinge-likedomains, and different geometries of hinge-like domains.

17. The protection gear of claim 1 as a programmable circuit board forarbitrary applications.

18. The protection gear of claim 1 fabricated using current flex circuitmanufacturing methods and materials.

19. The protection gear of claim 1 comprising a cloud storage to receivesensor data.

20. The protection gear of claim 1 where the polymer layers are currentflex manufacturing polymers such as Kapton, polyimides, polyamides,polyesters, or other as well as elastomers such as silicone rubbers(PDMS) or polyurethanes or other elastomers and the interconnects aremetals that have high electrical conductivity, such as copper or gold,or where the interconnects are conductive inks.

Custom Gear

In one aspect, the protective gear is custom formed to the athlete'sbody. This is done in FIG. 12C as follows:

-   -   321) perform 3D scan of person and create 3D model    -   322) form positive mold from the 3D model    -   323) place mold into 2 phase 3D printer to form a negative    -   324) put composite material into mold and form composite        protection gear    -   325) embed IoT electronics into one or more locations into the        composite protection gear    -   326) link IoT electronics with mobile devices and cloud based        storage and process impact data and warn user if impact is        unsafe.

The protection gear or footwear can be custom produced at the request ofa customer, who can specify the nature of the customization for one ormore pairs of helmet, protective gear, or footwear. Each helmet of thefootwear may have a different design, message or message portiondesigned into it and rendered using the bed of pins described below tomake the custom helmet or shoe design messages or shapes, and then thebottom sole can be fabricated using the reformable bed described below.Once the negative is fixed in the reformable bed, suitable materials forthe bottom sole can be deposited and cured and can include rubber,plastic, or foam. Further customization can be done by a ComputerizedNumerical Control (CNC) where component design can be integrated withcomputer-aided design (CAD) and computer-aided manufacturing (CAM)programs. The device can be programmed to use a number of differenttools-drills, saws, and so on. Alternatively a number of differentmachines can be used with an external controller and human or roboticoperators that move the component from machine to machine. Regardless, aseries of steps needed to produce a part can produce a part that closelymatches the original CAD design in a highly automated fashion. Inaccordance with aspects of the subject matter disclosed herein throughthe use of reformable bed and a suitably programmed CNC tools,customized footwear with custom cut sole designs, can cost effectivelybe created in small quantities and yet scalable for mass-customization.

1. A method of producing a component of customized wearable protectiongear, the method comprising:

capturing the 3D model of a person and adjusting the 3D model tocustomize a shape to optimize protection or performance;

using a rapid prototyping machine such as 3D printer or a bed of pins torender a positive model of the shape; and

impressing the positive model into a reformable mold to form thecomponent of the wearable protective gear.

2. The method of claim 1, wherein the component comprises a helmet,protective padding, shoulder padding, seat, shoe, or sole.

3. The method of claim 1, comprising fabricating a plurality ofcomponents in parallel.

4. The method of claim 1, wherein the component comprises shin guard,Helmet, Chin Strap, Chin Shields, Cup, Athletic Supporter, Elbow Sleeve,Arm Pad, Back Plate, Rib Protection, Facemask, Girdle, Helmet Visor,Shoulder Pad, Hip & Tail Pad, Mouthguard, Neck Roll, Knee Pad, Boot.

5. The method of claim 1, comprising joining the component with an upperto form a shoe.

6. The method of claim 5, wherein the shoe comprises a jogging shoe,basketball shoe, soccer shoe, miming shoe, climbing shoe, flip flop,sandal, or boot.

7. The method of claim 1, wherein the reformable mold comprises sandhaving a liquid state and a solid state.

Shock Protection

In one embodiment, the sole is not completely filled with material, butis formed as a lattice structure. The system generates triangulatedsurfaces for export to additive manufacturing (AM) processes.Implementing a process that coverts a CAD object into an image, known asvoxelisation, the company uses an image-based method which allowsdesigners to generate implicitly defined periodic lattice structuressuitable for additive manufacturing applications and finite elementanalysis (FEA). The system generates robust lattice structures canovercome the problems faced with hollowing out a part to reduce weightand optimize designs prior to 3D printing. Cellular lattice structurescan be used to replace the volume of CAD and image-based parts, reducingweight whilst maintaining optimal performance. In this way, the shoescan be light weight yet strong and provide shock impact absorptionduring running for the wearer.

Topology optimization can be used to drive the material layout includingthe lattice regions. From this new topology optimization implementation,the system can identify void regions in the design space, where thematerial can be removed, regions where solid material is needed, andregions where lattice structure is required. This allows the system togenerate the optimal hybrid or blended solid-lattice design based ondesired functionality of the part.

Lattice structures can be considered as porous structures. In the caseof topology optimization, the semi-dense elements are like the porousmedia. To refine the design, a second-phase involves a detailed sizingoptimization where the end diameters of each lattice cell member areoptimized. This allows for further weight reduction while meeting designrequirements, such as buckling, stress, and displacement.

A piezo material can be actuated to generate a vibration that cancelsincoming shock on the wearer. In one embodiment, the system tracks theshock such as the foot contact patterns and generates an anti-vibrationsignal to cancel the shock generated when the foot contacts the ground.In this embodiment, a processor receives foot ground contact using anaccelerometer. The stride pattern is determined, and the next footground contact is detected, and the piezo material is actuated with acounter signal to cancel the expected shock. This is similar to thenoise cancellation, except the vibration/shock is canceled.

In one hybrid embodiment, the shoes incorporate passive and activeisolation elements. The passive component consists of springs whichsupport the load weight and provide isolation over a broad spectrum.These springs provide a basic level of isolation in the lowerfrequencies and excellent isolation in the higher frequencies (above 200Hz). They also support the load while allowing for travel of theactuators in the active component. The performance of the springs isaugmented and corrected by an active isolation component. The activeisolation component consists of vibration sensors, control electronics,and actuators. The vibration sensors are piezo accelerometers. Aplurality of sensors in each isolation system are positioned indifferent orientations to sense in all six degrees of freedom. The piezoaccelerometers convert kinetic vibration energy into electrical signalswhich are transmitted to the control electronics. The electronicsreconcile and process the signals from the various sensors using aprocessor. The electronics then send a cancellation signal to theactuators. The actuators generate vibrations that are equal to theincoming vibrations but out of phase in relation to the incomingvibrations. This results in cancellation of the incoming vibrationalnoise, leaving the wearer undisturbed. This process occurs within 5-20milliseconds of a vibration entering the system.

Multi-Phase Manufacturing (MPM)

While conventional additive manufacturing 3D printers can be used formass-customization of the shoes, the material available is limited andthe print speed is slow, leading to fragile and expensive shoes. FIGS.13A-13D and 14A-14D show exemplary systems and techniques formanufacturing in volume with a wide range of materials are disclosed forfabricating custom protective gears, helmets, pads, or shoes at masscustomization scale. The system can also be further cleaned up aftermanufacturing using CNC for smoothing the soles, stiching fabrics ontothe sole, or any other required post-processing manipulation of thefabricated shoes.

In one aspect, systems and methods are disclosed for shaping areformable material by holding a volume of particles inside a containerhaving a first elastomeric membrane surface; infusing the volume with aliquid to mobilize the volume of particles; and pressing a master shapeinto the membrane with atmospheric pressure.

In another aspect, a method to form an object includes infusing a liquidinto a container having a first elastomeric membrane surface; pressing amaster shape into the membrane with atmospheric pressure; and shaping areformable material into the object according to the master shape.

In yet another aspect, a method to form an object includes infusing aliquid into a container having a frame with first and second elastomericmembranes; a first port to deaerate the volume of particles; and asecond port to infuse the volume with a liquid for mobilizing the volumeof particles; pressing a master shape into the membrane with atmosphericpressure; and shaping a reformable material into the object according tothe master shape.

Implementations of the above aspects may include one or more of thefollowing. The volume of particles can be deaerated. The liquid can beextracted through one or more screen elements placed proximal to thevolume of particles. The atmospheric pressure continues to hold theparticles in place against the elastomeric membrane when the mastershape is removed from the outer surface of the membrane. The methodincludes heating and driving liquid from the particle volume. A residueof a binding adhesive is left to lock the particles into a continuousforce-resisting mass. A complementary shape is impressed to the mastershape in the membrane. A rigid outside frame can be used with top andbottom elastomeric membranes facing the top and bottom surfaces of thecontainer. The master shape can be pressed against the top elastomericmembrane of the container by atmospheric pressure. The pressingoperation includes applying a flexible vacuum cap which is sealed overthe shape and against the container's top surface membrane; evacuatingair from a space between the top membrane and the vacuum cap; extractingliquid from the volume; and pressing the particles within the containerby atmospheric force acting in opposed directions against the vacuum capand the bottom surface membrane. Air can be introduced into the vacuumcap, and then the cap and the master shape can be removed from theformed surface of the elastomeric membrane. The container is formedagainst the master shape. The method includes placing the master shapeon an air-impermeable surface; placing a membrane of the container overthe shape; and placing a vacuum cap or a vacuum-bagging film over thecontainer to effect forming of the elastomeric membrane against themaster shape. An envelope with a vacuum seal on its perimeter can beused to contain a mass of particles and to extract air from between themaster shape and the envelope. The master shape can be placed on the topelastomeric surface of a first rigid-framed container and a membranesurface of a second container can be placed over the master shape. Thesecond container fits inside the frame of the first container and avacuum cap is placed over and sealed outside the second containeragainst the surface membrane of the first container. The method includesevacuating the volume under the vacuum cap and pressing the master shapebetween the elastomeric sides of the first and second containers. Theliquid is extracted so that the two volumes of particles are pressedtogether and against the membranes surrounding the contained shape. Thevacuum cap can be vented with air and removed; the top container canthen be removed; and the shape can then be removed from the membrane ofthe bottom container. The top container can be placed over the bottomcontainer; and forming a closed, shaped cavity complementary to thesurface of the master shape used to form the cavity. Two identicalcontainers of either the first or the second container can be pressedaround a master shape with or without using the vacuum cap. Thecontainers can be joined and sealed by either a seal mounted on one orboth of the containers or by seals mounted on a seal ring which fitsbetween the two containers. The liquid can be extracted prior to themaster shape being removed from the shaped reformable material. Theliquid can be withdrawn to leave a residue of liquid on the shapedreformable material; and solidifying the residue. The method can includepreforming a surface material over the master shape as withthermoforming or additive processing. The container walls can be air andliquid impermeable. An inelastic formable surface can be used thatconforms to the master shape surface. A surface can be formed over themaster shape to conform to the master shape and the shaped materialsurface can be pressed against the volume of particles without deformingthe shaped material surface. The method includes providing a releasesurface to the master shape; pressing the master shape against thevolume of particles to form the object against the release surface; andremoving the object from the master shape with the release surface. Therelease surface can be applied to the master shape with a surfaceelement covering the reformable material surface not overlaid with themaster shape surface.

In another aspect, an apparatus to form an object in accordance with amaster shape includes a container to hold a volume of particles, saidcontainer having a first elastomeric membrane surface; a first port todeaerate the volume of particles; and a second port to infuse the volumewith a liquid for mobilizing the volume of particles; and a presscoupled to the container to move the master shape into the membrane toshape a reformable material into the object according to the mastershape.

Implementations of the above aspect may include one or more of thefollowing. One or more screen elements can be placed proximal to thevolume of particles to extract the liquid. Atmospheric pressure can beused to hold the volume of particles in place against the elastomericmembrane when the master shape is removed from the membrane. A heatercan be used to heat and drive liquid from the particle volume. Thecontainer can be a rigid outside frame and top and bottom elastomericmembranes facing the top and bottom surfaces of the container, andwherein the master shape is pressed against the top elastomeric membraneof the container by atmospheric pressure. The apparatus can include aflexible vacuum cap sealed over the shape and against the container'stop surface membrane; a third port to evacuate air from a space betweenthe top membrane and the vacuum cap; and pressing of the particleswithin the container by atmospheric force acting in opposed directionsagainst the vacuum cap and the bottom surface membrane. Air can beintroduced into the vacuum cap and then the cap and the master shape canbe removed from a surface of the elastomeric membrane. The master shapecan be placed between an air-impermeable surface and the membrane of thecontainer and wherein a vacuum cap or a vacuum-bagging film is placedover the container to form the elastomeric membrane against the mastershape. An envelope with a vacuum seal on its perimeter can be used tocontain a mass of particles and to extract air from between the mastershape and the envelope. The master shape can be placed on the topelastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape. The secondcontainer fits inside the frame of the first container and a vacuum capis placed over and sealed outside the second container against thesurface membrane of the first container. A vacuum pump can evacuate thevolume under the vacuum cap and press the master shape between theelastomeric sides of the first and second containers. A pump can extractthe liquid so that the two volumes of particles are pressed together andagainst the membranes surrounding the contained shape. The vacuum capcan be vented with air and removed; the top container is removed; andthe shape is removed from the membrane of the bottom container and thetop container is placed adjacent the bottom container to form a closed,shaped cavity complementary to the surface of the master shape used toform the cavity. The first and second containers can be identical andcan be pressed around a master shape without using the vacuum cap. Thecontainers can be joined and sealed by either a seal mounted on one orboth of the containers or by seals mounted on a seal ring which fitsbetween the two containers. A seal ring can be used to channel vacuum orair pressure between the containers and to hold the master shape in aprecise orientation and position between the two opposed containers. Anexpander can be used within the container to press the particulatematerial against cavity walls of the container. The apparatus caninclude a second container cooperating with the first container to forma complementary cavity from the master shape; and a third containerplaced in the complementary cavity to replicate the master shape. Arigid frame or a flexible-edge frame can be used. The frame can form acontinuous surface complementary to a master shape's surface. A secondelastomeric membrane can be used, and the elastomeric membranes canoverlap or abut each other. Additional containers each having a membranecan be used with the container's membrane to form a continuous surfaceof membranes. Further, additional containers can be used to form a shapecomplementary to the interior of a master cavity.

In another aspect, an apparatus to form an object in accordance with amaster shape includes a container to hold a volume of particles, saidcontainer having a frame with first and second elastomeric membranes; afirst port to deaerate the volume of particles; and a second port toinfuse the volume with a liquid for mobilizing the volume of particles;and a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape.

Implementations of the above aspect may include one or more of thefollowing. The second membrane is bonded to the frame. The firstmembrane is mounted to a seal. A clamp can secure at least one membraneto the frame. One or more ports can be provided on the frame. Liquid,evacuation, and vacuum-activated seal tubes can be mounted to the frame.A rim evacuation screen element can be positioned in the frame. Theframe can be rigid or flexible. A vacuum activated seal can be providedon the frame. A tube can be used for evacuating and filling thecontainer. Double layer screens having feed elements to distribute andextract liquid through the volume of particles can be used. One or morescreens can be used to conform to the master shape. One or more internalscreens can be mounted with the particles flowing on both sides of eachinternal screen. The frame can have one or more containers joinedtogether around the master shape or alternatively can have one or morecontainers joined by vacuum seals. One or more feed tubes can connect toan interior element inside the membrane. A flexible spine element can beused within an interior cavity of the container. One or morereinforcement fibers can be used, and in certain implementations, thefibers can be distributed in bundles within the volume of particles. Anair pump or source can be used to provide internal pressurization. Avacuum source can provide a vacuum between a cavity in the container andthe container. An air source and a vacuum source can alternatelypressurize and vent the container to distribute the volume of particlestherein. A seal ring can be used. The seal rings can be mounted againstseals or can be mounted with attached seals. The attached seals can bevacuum activated. A second container can be joined with the containerand wherein a vacuum is formed in an interior of the joined containers.The master shape can be mounted on the seal ring. Flanges can be mountedto control a mating line between opposed membranes of containers. Asecond container can be positioned within a cavity formed by an outsidecontainer. A vacuum seal can be used with a vacuum cap. A vacuum tubecan be used that penetrates through the membrane. A vacuum cap withmounted container can be used in place of the membrane. One or morescreen elements can be placed proximal to the volume of particles toextract the liquid. Atmospheric pressure holds the volume of particlesin place against the elastomeric membrane when the master shape isremoved from the membrane. A heater can be used to heat and drive liquidfrom the particle volume. The container can have a rigid outside frameand top and bottom elastomeric membranes facing the top and bottomsurfaces of the container, and wherein the master shape is pressedagainst the top elastomeric membrane of the container by atmosphericpressure. An envelope with a vacuum seal on its perimeter can containthe mass of particles and extract air from between the master shape andthe envelope. The master shape can be placed on the top elastomericsurface of a first rigid-framed container and a membrane surface of asecond container placed over the master shape. An expander within thecontainer can be used to press the particulate material against mastershapes and against cavity walls of other containers. The apparatus canhave a second container cooperating with the first container to form acomplementary cavity from the master shape; and a third container placedin the complementary cavity to replicate the master shape. A secondelastomeric membrane can be used that either overlaps or abuts theadjacent membrane. Additional containers each having a membrane coupledto the container can be used to form a continuous surface of membranes.Additionally, one or more additional containers can form a shapecomplementary to the interior of a master cavity.

In yet another aspect, a base station is disclosed to form an object inaccordance with a master shape. The base station includes a liquidreceiver; a vacuum source to evacuate air from the liquid receiver; anair compressor, pump or source to generate pressurized air; and acontroller coupled to the liquid receiver, the vacuum source and the aircompressor to form the object.

Implementations of the base station can include one or more of thefollowing. Tubes can be used to provide vacuum and to control the flowof liquids to and from the receiver. Valves, sensors, and other circuitscan be interfaced with the controller. An electrical power source can beused to provide power to operate valves, sensors, the vacuum pump andthe air compressor. The controller can be a menu-driven processcontroller. A heater can be used to vaporize and expel liquid fromcontainers of reformable material. The reformable material createscontours of the master shape or alternatively can be molded against acomplementary surface of an elastomeric membrane. The liquid contains asoluble binder, which can be left on a shaped volume of particles. Thebinder locks a shaped volume of particles in place after the liquid isremoved. The heater can be a radiant heater, a convective air heater,microwave heater, radio-frequency heater, or inductive heater. Theheater can include one or more heating elements within the container.The heater is controlled by the controller. A container can be used tohold a volume of particles, said container having a frame with first andsecond elastomeric membranes; a first port to deaerate the volume ofparticles; and a second port to infuse the volume with a liquid formobilizing the volume of particles; and a press coupled to the containerto move the master shape into the membrane to shape a reformablematerial into the object according to the master shape. Alternatively,the container can have a first elastomeric membrane surface; a firstport to deaerate the volume of particles; and a second port to infusethe volume with a liquid for mobilizing the volume of particles; and apress coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape. The container can include a rigid outside frame and topand bottom elastomeric membranes facing the top and bottom surfaces ofthe container, and wherein the master shape is pressed against the topelastomeric membrane of the container by atmospheric pressure. The basestation can also include a flexible vacuum cap sealed over the shape andagainst the container's top surface membrane; a third port to evacuateair from a space between the top membrane and the vacuum cap; andpressing of the particles within the container by atmospheric forceacting in opposed directions against the vacuum cap and the bottomsurface membrane. The master shape can be placed between anair-impermeable surface and the membrane of the container and a vacuumcap or a vacuum-bagging film can be placed over the container to formthe elastomeric membrane against the master shape. The vacuum pump canbe a mechanical pump or an air driven pump such as a Venturi pump. Asecond vacuum pump can be used. Isolating valves can be used, and aregulator and one or more valves can be used to pressurize a liquidtank. A vent valve can also be used to cycle from a vacuum source to apressure source. A three-way valve can route air and vacuum to theliquid tank. A filter can be used to prevent particulate carryover. Anair-liquid separator and/or a level indicator can also be used. Avacuum, pressure, liquid and temperature sensor can provide data to thecontroller for process control. A heat exchanger can be used to condensevapor. A slurry transfer tank can be connected to the container. Thecontainer can be a single unit, or can have a plurality of containersadjacent to or inside the container to form a cavity. The containers canbe mated with a seal ring.

In yet another aspect, a method to shape a reformable material includesholding a volume of particles inside a container having a firstelastomeric membrane surface; and infusing the volume of particles witha liquid; agitating the liquid to provide one or more surges of liquidto mobilize the volume of particles; and pressing a master shape intothe membrane with atmospheric pressure.

Implementations of the above method may include one or more of thefollowing. The method may provide locally distributed surges or globallydistributed surges. The surges can exert differential liquid forces onparticles to displace them relative to one another and facilitate theirmovement into a closely-packed volume. A differential pressure can beapplied between a master shape side and a liquid-particle side of themembrane. The pressure between a vacuum cap and the membrane can bedecreased to move the membrane in a first direction or increased to movethe membrane in a second direction. The membrane is free to moverelative to the master shape. Excess liquid can be removed to leaveparticles against the membrane. Air can be evacuated from space betweenthe membranes. The particles can be packed against the membranes and themaster shape. The liquid with the vacuum cap and membrane pressedagainst the master shape can pack the particles against the membranesand the master shape. The agitating operation can include pulsing orvibrating the liquid. The vibration frequency can be adjusted todisplace one particle relative to another to keep the particles movingfreely in relation to one another. The amplitude of the liquid pulsationcan be proximally equal to a diameter of the particles. A first surge ofliquid can be directed towards a desired transport direction and asecond surge smaller than the first surge can be directed in an oppositedirection to the transport direction. The agitating of the liquid can beused to minimize blockage. The method includes maintaining the volume ofthe container constant and completely filled to force the particlesagainst the master shape. The method includes extracting transitionalliquid from the container; and adding new liquid equal in volume to thetransition liquid.

In yet another aspect, a shape-reformable composition includes a carriermedium having a carrier density; and a plurality of solid bodies havinga density substantially similar to the carrier density, said solidbodies being transitionable from a formable state to a three dimensionalsolid shape. The bodies can have a density substantially lighter orheavier than that of the carrier if they have a high ratio of surfacearea to volume. The bodies can be stiff, flexible or elastomeric. Thebodies can be regular or irregular and can be of substantially differenttypes intermixed.

Implementations of the composition can include one or more of thefollowing. The carrier medium fills voids or interstices between thesolid bodies such that the voids or interstices are free of air or gasbubbles. The solid bodies can have near-liquid or fluent mobility duringthe formable state. The solid bodies can transition to the solid shapethrough an introduction and an extraction of a predetermined amount ofthe carrier medium. The solid bodies can be positioned in a containerhaving a first elastomeric membrane surface. Liquid can be introduced tomobilize the volume of particles. A master shape can be pressed into themembrane with atmospheric pressure. The resulting solid shape is astable, force-resisting shape. The solid bodies and carrier medium forma reversible state-changeable mixture. The carrier medium can be aliquid or a gaseous froth. The shape can be a reformable mold or areusable template to capture dimensions of impressed shapes for transferto a mold.

In other aspects, a system is disclosed for holding a volume ofparticulate material inside an air and liquid-impermeable container withat least one elastomeric membrane surface; deaerating the volume;infusing the volume with a liquid to cause it to be mobile; pressing amaster shape into the membrane via atmospheric pressure; and extractingthe liquid through one or more screen elements which are placed in oradjacent to the particle volume. The extraction causes atmosphericpressure to press the particles against the contours of the shape andagainst each other. This pressure continues to hold the particles inplace against the elastomeric membrane when the master shape is removedfrom the outer surface of the membrane. The system further has a meansto heat and drive liquid from the particle volume and, in certainembodiments, to leave a residue of binding adhesive which locks theparticles into a continuous force-resisting mass.

Operation of one embodiment is as follows with a particular embodimentof the container which has a rigid outside frame and a membrane face onthe top and bottom surfaces. With the particle volume infused by liquid,a master shape is pressed against the top elastomeric membrane of thecontainer by atmospheric pressure, thereby causing the shape to impressa complementary shape in the membrane. This pressing is accomplishedthrough use of a flexible or elastomeric vacuum cap which is sealed overthe shape and against the container's top surface membrane, followingwhich air is evacuated from between the top membrane and the vacuum cap.Liquid is then extracted from the volume and the particles within thecontainer are pressed together by atmospheric force which acts on allexterior surfaces of the tool-bed but in particular in opposeddirections against the vacuum cap and the bottom surface membrane. Airis then introduced into the vacuum cap, the cap removed and the mastershape removed from the formed surface of the elastomeric membrane.

In another embodiment, the container is formed against a master shapewith the process of liquid infusion, a pressing action via atmosphericpressure and a liquid extraction process. This embodiment is essentiallya flat envelope with a flexible outside rim and two opposed elastomericmembranes. To use this embodiment a master shape is placed on anair-impermeable surface, a membrane of the container is placed over theshape, and either a vacuum cap or a vacuum-bagging film is placed overthe container to effect forming of the elastomeric membrane against themaster shape. The envelope may also have a vacuum seal on its perimeterand so has the combined function of containing a mass of particles andof serving to extract air from between the master shape and theenvelope.

In implementations, there can also be a combined use of the first andsecond containers described above. A master shape may be placed on thetop elastomeric surface of the first rigid-framed container and then amembrane surface of the second container is placed over the shape. Thesecond container fits inside the frame of the first container and avacuum cap is placed over and sealed outside the second containeragainst the surface membrane of the first container. When the volumeunder the vacuum cap is evacuated the master shape is pressed betweenthe elastomeric sides or faces of the two containers. Liquid is thenextracted so that the two volumes of particles are pressed together andagainst the membranes surrounding the contained shape; the vacuum cap isvented with air and removed; the top container is removed; and the shapeis removed from the membrane of the bottom container. When the topcontainer is again placed over the bottom container, a closed, shapedcavity is formed which is complementary to the entire surface of themaster shape which was used to form the cavity.

In yet another embodiment, a combination of containers can be used inwhich two identical containers of either the first or the second typemay be pressed together around a master shape without use of the vacuumcap. In this case the containers are joined and sealed by either a sealmounted on one or both of the containers or by seals mounted on a sealring which fits between the two containers. The seal ring may be furtheremployed to channel vacuum or air pressure between the two containersand to hold the master shape in a precise orientation and positionbetween the two opposed containers. The seal ring may also furnishaccess to the formed cavity for the purpose of injecting a moldablematerial into the cavity.

In yet another embodiment of the container the container itself isformed into a replica of a master shape, or into a shape complimentaryto a master cavity by another combination of the elements and processesdescribed above. The exterior of this third type of container may beformed entirely from an elastomeric material or may be formed from acombination of elastomeric, flexible and rigid materials. Though thecontainer might be shaped against a single surface, it can also beshaped over substantially its entire surface by confining it within amaster cavity formed by two or more closely-fitting mold parts. Key tothis forming process is an expansion means within the third containerwhich presses the particulate material against the cavity walls.

In another embodiment, there is combined use of the containers whichemploy the three types of containers described above for a singlepurpose. The first or second types can be used to form a complementarycavity from a master shape. The third type of container can then beplaced in the cavity, which is now used as a master cavity, and thethird type formed complementary to the master cavity contours, therebycreating a replica of the original master shape.

It can be appreciated that there are numerous variations of containersand varied combinations of containers which can be employed either toform a surface which is complementary to the exterior surface of amaster shape in part or in whole, or to form a surface or surfacescomplementary to the interior contours of a hollow master shape ormaster cavity. For instance more than one container of the first type(rigid frame) or second type (flexible-edge) can be employed to form acontinuous surface complementary to a master shape's surface, with theelastomeric membranes of the containers either overlapping or beingabutted together. Containers of the second type may also have a membraneand particle configuration that allows two or more of the containers tobe “tiled” together to form a continuous surface of particle-backedmembranes. Likewise two or more containers of the third type can beemployed together to form a shape complementary to the interior of amaster cavity.

In yet other embodiments, a forming system also includes a base stationwhich provides evacuation of air, liquid infusion into and liquidextraction from the particle filled containers. The base station alsofurnishes vacuum forces to enable the forming operations to be performedon the various containers either singly or in combination. The basestation comprises a liquid receiver; onboard vacuum system or provisionto connect to an external vacuum source; an air compressor or provisionfor external connection to pressurized air; valves, fittings and tubingor piping to provide vacuum and to control the flow of liquids to andfrom the containers; an electrical power supply to operate the valves,process sensors and any onboard mechanical vacuum pumps and aircompressors; and a menu-driven process controller to operate the basestation.

In another embodiment, a forming system includes a heater which may beused to vaporize and drive out liquid from the particle filledcontainers, and further to heat any materials which may be used torecreate the contours of the original master shape through moldingagainst the complementary surface of the formed elastomeric membrane.The vaporizing or drying process is especially advantageous when theliquid contains a soluble binder which remains on the pressed-togetherparticles and locks the shaped volume of particles in place when theliquid has been driven out of the container. The heater may takenumerous forms to include a radiant heater, a convective air heater,heating elements within the particle-filled container, and various typesof inductive (e.g., microwave or radio-frequency) heaters. The heatermay be powered and controlled by the base station and its controller, orthe heater may be powered and controlled separately.

Next a reformable shoe making embodiment is detailed. In this system,the 3D model of the shoe as customized by the user or a doctor for theuser is sent 1003 is provided to a reformable shape object fabricator1006, which is detailed next. The fabricator 1006 renders a physicalmodel of the 3D model and then applies a state-changeable mixture thatincludes uniform, generally ordered, closely-spaced solid bodies and aliquid carrier medium, with the liquid filling any voids or intersticesbetween the bodies and excluding air or gas bubbles from the mixture.Within the mixture, the solid bodies can be caused to transition from anear-liquid or fluent condition of mobility to a stable, force-resistingcondition. To create mobility, a small excess quantity or transitionliquid is introduced to create a fluent condition by providing a slightclearance between the bodies which permits the gently-forcedintroduction of at least two simultaneous slip planes between orderedbulk masses of the bodies at any point in the mixture. Transition to thestable condition is caused by extraction of the transition liquid,removing the clearance between bodies and causing them to make stable,consolidated contact. FIG. 4A shows a computer controlled system forfabricating parts that whose dimensions are specified in a data file andrendered by a CAD/CAM software such as Solidworks or Autocad or evenPaint, and the object described in the data file needs to be fabricated.Conventional printers print a layer at a time and can take significanttime in making a single product. To accelerate the production process,the system of FIG. 4A takes 3D data from a computer with 3D CAD design1002 and provides the information to an actuated 3D shape generator 1004that is placed inside of a reformable object copier 1006. The 3D shapegenerator 1004 forms the 3D object, and the object copier 1006reproduces copies of the formed 3D object in minutes, thus greatlyaccelerating production of mass-customized products which otherwisetakes hours on a 3D printer.

The 3D shape generator 1004 is a complete computer actuated system thatis enclosed in the object fabricator 1006. CAD data is downloaded bywire or wireless connection to the shape generator 1004. Based on thedesired dimensions, one embodiment of the 3D shape generator 1004 formsa 3D object by having an array of computer controlled moveable pinswhose height is adjusted in accordance with the CAD design file, and theoverall shape is smoothed by a Lycra sheet or felt sheet. The pins orrods lift the felt or Lycra sheet to form a 3D object based on the CADdesign file. In this embodiment, an array of N×N micro hydraulicactuators can be used to form the shape. This embodiment is a densehydraulic planar pin-rod matrix array. Another embodiment actuates anN×N pin-rod matrix driven by servomotors. In either case, each pin-rodis controlled individually, similar to pixels on a screen except thatthe pixel has height as well.

In one embodiment, the N×N matrix can be an array of electro-mechanicalpins positioned in a frame. The frame is adapted to hold the pluralityof pins in a parallel position to one another in a series of columns androws, such that the distal ends of the plurality of pins together form aflat virtual plane. Each pin of the plurality of pins includes anelongated housing member defining a linear axis therethrough, and a pinmember adapted to slide linearly in either direction along the axis.Each of the housing member includes an upper electromagnet, and a lowerelectromagnet separated from the upper electromagnet. Each of theelectromagnet is adapted to move its respective pin member linearly ineither direction. Each of the pin member includes a linearpotentiometer, a, magnet and an electronic transmitter attached to anopposite end to the distal end, such that when each of the pin membersare moved linearly each respective linear potentiometer sends a signalto its respective transmitter which in turn sends an electronic signaldescribing its movement within its respective housing member, aplurality of electronic wires respectively connected to eachtransmitter, such that electronic signals can be relayed to and fromeach respective pin; an analog-digital converter connected to theplurality of electronic wires and adapted to convert the analogelectronic signals relayed by the transmitters into digital format to betransmitted, processed, stored, and then converted back into analog formfor return transmittal to the set of pins. A processor is connected tothe converter and adapted to retrieve the electronic signals from theconverter, store them, and retransmit them back to the converter whendesired, such that a user can displace the pin members from the virtualplane in any pattern, have electronic signals sent, processed, stored,and returned to the same set of pins, or another separate set of pins,at a later time to thereby displace the pins to the same positions asthe original pattern chosen by the user.

In one embodiment, the pin array device has each of the housing memberof each pin comprise an upper frame upper electromagnet, upper spring,lower electromagnet, lower spring and shield along the entire upperframe wall to separate magnetic field between each interactive pin. Thelower frame consists of the outer fixed part of the potentiometer andelectronic transmission from electronic transmitter to bothelectromagnets. The pin consists of a magnet, a mobile portion of thepotentiometer, electronic transmitter that picks up all the wire andsends position signal and feeds the power to both electromagnets via thelower housing. The electronic signal may be a Pulse Width Modulationsignal, and the displacement of each of the pin members is proportionalto the strength of the Pulse Width Modulation signal received by theelectromagnets.

FIG. 14B shows the shape of the object when a felt cover or a Lycracover is placed above the pins to form a 3D structure that can bedigitally controlled using a CAD output to form a 3D object that canthen be copied or fabricated using the reformable object fabricator1006.

In yet another embodiment shown in FIGS. 2C-2D, the pins are moved bythe action of a plate, common to all or a portion of the pins, that canextend and retract along a single axis of motion. A clutch mechanismcooperates with the moving plate to fix the pins at a desired position.In an exemplary embodiment, the shape generator 1004 can include amembrane covering the pins. A plurality of pins 1011-1018 arranged in anarray such that respective head portions 1021-1028 associated with thepins collectively define a surface 1030. It will be appreciated that thearea of array is not necessarily defined by two Cartesian dimensions.For example, the pins could be arranged along a spherical orhemispherical surface, with the array spanning the azimuthal and polardimensions across the surface of the sphere. The position of a given pin(e.g., 1011) can be adjusted along an axis of motion.

In one embodiment, an optional motion plate 1032 can be provided to movethe pins along the axis of motion as to adjust the position of the pins.The motion plate 1032 can be moved by reasonable mechanical orelectromagnetic means. For example, the plate 1032 can be moved via anelectrical motor, a hydraulic assembly, or one or more solenoid coilsexerting a magnetic force.

A clutch mechanism 1034 is operative to arrest the motion of a given pinat a desired position. The respective positions of the pins can beselected to deform the display surface into a desired raised image. Theclutch mechanism can comprise reasonable means for selectively arrestingthe motion of the pins. For example, the clutch mechanism 1034 cancomprise components for mechanically or magnetically engaging the pins.

One embodiment provides an upper plate with a plurality of aperturesthrough which corresponding pins forming the object's surface can pass.The pins can include head portions with areas larger than that of theirrespective apertures, to more fully tessellate the display surface andto help maintain the pins within the apertures. The upper plate canhouse part or all of a clutch mechanism that selectively engages one ormore pins to maintain the pins at a desired position. The upper platehouses one or more banks of solenoids that shift the position of one ormore portions of the clutch (not shown) that physically communicate withthe pins. In an exemplary embodiment, the solenoids shift the positionof one or more bars such that they contact or release circumferentialgrooves on the surface of the pins. This embodiment also provides alower plate and a base plate disposed parallel to the upper plate alongone or more support posts. A lifting plate can be suspended between thelower plate and the base plate on one or more guide posts. The liftingplate can be raised or lowered via a motor and belt system to adjust theposition of the pins. For example, the pins can be reset to a fullyraised position by raising the lifting plate to its maximum height. Themovement of the guide pins and the action of the clutch mechanism can beregulated by a processor.

FIG. 14D illustrates a side view of an exemplary computer shaped objectthat can be reproduced or fabricated formed in accordance with an aspectof the present system. As shown in FIG. 2E, two facing and opposite bedof pins 2210-2212 can form a 3D shape for the sole or insert. The insertand/or the shoe can be produced in discrete sizes such as US sizes 4,4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12,12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, and 18, forexample. Thus, a plurality of sized beds can be used, or one large pairof beds covering size 20 can be used to produce all other smaller sizes.Turning back to FIG. 2D showing one of the beds 2210-2212, the selectedview of the 3D object creator comprises one row of four pins 2102-2108.It will be appreciated that a functioning computer controlled 3D objectcreator can contain a large number of pins arranged across multiple rowsin order to reproduce the shape of the 3D object with high fidelity.

In an exemplary embodiment, the rows containing the pins 2102-2108 arestaggered as to form a honeycomb pattern. Accordingly, the pins2102-2108 are arranged in a plurality of linear rows and one or morestaggered columns. Alternatively, the pins can be arranged in aCartesian grid, such that both the rows and the columns are linear. Itwill be appreciated that other methods of arranging the pins can beutilized, and that the placement of the pins will vary with thenecessary size and spacing of the pins, as well as the desired shape(e.g., flat, spherical, recessed) of the array.

In the illustrated display, the pins 2102-2108 have respective capportions 2112-2118 that define a raised surface. The cap portions2112-2118 can be covered by an elastic membrane or felt layer 2120 toprovide a relatively smooth surface for the object. The use of the pincaps 2112-2118 and the membrane 2120 will depend on the application. Thepins 2102-2108 pass through respective apertures in a stationary, outerplate 2124. The outer plate 2124 houses a clutch mechanism 2126 thatacts to maintain the pins in their desired positions. In an exemplaryimplementation, the clutch mechanism 2126 can comprise a series of rowbars and column bars having two associated positions. In a first, open,position, a given bar allows the pins within its associated row orcolumn to move freely. In a second, restraining, position, the bar ismoved to physically contact the pins at one of a plurality of evenlyspaced grooves on the pin, maintaining the pin at its position. Thespacing of the grooves corresponds to a desired resolution of thedisplay 2100. The position of the bars can be changed via one or morebanks of solenoids. In an exemplary embodiment, the bars are biased, bya spring or similar mechanism, to remain in the restraining position,until a solenoid is actuated to move the bar into an open position.

During operation, the pins can be reset into a fully extended positionby a reset plate 2130. The reset plate 2130 can then be incrementallywithdrawn to allow the pins 2102-2108 to retract toward the interior ofthe display device. In an exemplary embodiment, the reset plate 2130 ismoved by a motor and belt arrangement. The pins 2102-108 have associatedsprings 2132-2138, with each spring (e.g., 2132) attached at a first endto the underside of the outer plate 2124 and at a second end to the endof the pin (e.g., 2102) opposite the cap portion (e.g., 2112). When thepins 2102-2108 are fully extended, the springs 2132-2138 are compressedagainst the underside of the outer plate 2124. The springs 2132-2138thus provide a tensive force on the pins 2102-2108 as to draw the pinstoward the interior of the object being formed.

The movement of the reset plate 2130 and the operation of the clutchmechanism can be coordinated by a controller 2140 to adjust the positionof the pins 2102-2108. The controller 2140 can provide informationrelating to the desired pin positions to the projector. The reset plate130 can be incrementally withdrawn toward the interior of the object. Inan exemplary embodiment, the reset plate 2130 withdraws in incrementsequal to the spacing between the grooves on the pins 2102-2108. Aftereach retraction of the plate, the clutch mechanism 2126 can beselectively activated to release one or more of the pins, while leavingothers secured. The tensive force provided by the springs 2132-2138pulls the ends of the released pins flush against the reset plate 130,such that the released pins retract to a uniform level defined by theposition of the reset plate. The secured pins remain at their previouslevel. The pins are then resecured by the clutch mechanism, and theplate is retracted by another increment. This process is repeated as thereset plate 2130 retracts to leave each pin at a desired level ofextension.

In another embodiment, the pins pass through respective apertures in astationary, outer plate housing a first portion of a clutch mechanismthat acts to adjust the pins into desired positions. In an exemplaryimplementation, the first clutch portion can be piezoelectric restraintsfor the plurality of pins. In a default position, a given restraintloops around its associated pin, but allows the pin to move freely. Uponthe application of an electrical current, the restraint contracts as tophysically contact its associated pin at one of a plurality of evenlyspaced grooves on the pin. This fixes the pin to the outer plate,maintaining the pin at a stationary position. The spacing of the groovescorresponds to a desired resolution of the 3D object being formed. Thepins also pass through respective apertures in a moving plate which canbe moved by a motor and belt arrangement. The moving plate houses asecond portion of the clutch mechanism with piezoelectric restraints forthe plurality of pins. The movement of the moving plate and theoperation of the first/second clutch portions can be coordinated by acontroller to adjust the position of the pins. The moving plateoscillates in a direction normal to the outer plate and a base platebetween a first position, closest to the base plate and a secondposition, closest to the outer plate. In an exemplary embodiment, thefirst position and the second position are separated by a distance equalto the spacing between adjacent grooves. The pins begin in a defaultposition, fixed to the outer plate by the first clutch portion. In anexemplary embodiment, the default position of the pins is a fullywithdrawn position (e.g., the first clutch portion engages the uppermostgroove of each pin). Since the default position of the pins is known,the controller can determine the distance between the default positionand a desired position as a number of increments, as defined by thegroove spacing of the pins. The controller can thus select one or morepins to extend by one or more increments. While the moving plate is inits first position, the selected pins are released by the first clutchportion. Simultaneously, the second clutch portion engages the selectedpins, such that the pins are fixed to the moving plate. The moving platecan then be moved to its second position. Once the plate reaches thesecond position, the second clutch portion releases the selected pins,while the first clutch portion reengages the pins. It will beappreciated that the motion of the moving plate can be controlled by thecontroller such that the first clutch portion can engage the pins at agroove one increment below the default position. Accordingly, theselected pins are extended by one increment. This can be repeated anumber of times, to allow one or more pins to be moved to a desiredposition up to a maximum extension. The final position of each pin willbe determined by the number of times the first and second clutchportions are activated for the pin. This can be controlled by thecontroller according to the desired position of the pin. Once the pinshave been positioned, the controller can direct the object fabricator1006 to copy the 3D object formed by the pin grid 3D shape generator.

In another exemplary clutch mechanism, a pin can be encased in a solidrestraining material having a low melting point. For example, therestraining material can be an alloy of lead and one or more othermetals. The restraining material is contained in a container having arelatively high melting point. The clutch mechanism disengages byapplying heat from a heat source to the restraining material in order tobring it to a liquid state. The heat source can be applied by a laserapparatus (not shown) directed on the restraining material or by aheating element associated with the container. In an exemplaryimplementation, the container is the heat source, producing resistiveheat upon the application of an electrical current. While therestraining material is in a liquid state, the pin can move freelythrough the aperture. Once the heat source is deactivated, therestraining material cools and returns to a solid state, restraining thepin.

In yet another exemplary clutch mechanism, a wire has shape memoryproperties is looped around a pin. The material with shape memoryproperties has the ability to return to an imprinted shape when heated.A desired shape can be imprinted into the material by molding thematerial at a high temperature and maintaining the desired shape as itcools. Below a threshold temperature, the material is relativelyflexible and can be deformed away from the imprinted shape with relativeease. Once the material is heated above the threshold temperature,however, it reverts back to the imprinted shape with some force. In anexemplary implementation, the wire is a formed from nitinol, an alloy ofnickel and titanium. The wire is shaped such that the loop is openedaround the pin and the pin can move freely through the loop. A currentcan be applied to the wire to heat the wire via resistive heating to atemperature greater than its threshold temperature. This causes the wireto return to its imprinted shape, engaging the pin as the loop closes.The wire returns to its imprinted shape somewhat forcefully, such thatthe tensive force on the ends of the wire is insufficient to restrainit. In an exemplary embodiment, the wire is looped around a groove inthe surface of the pin to facilitate engagement of the pin. When thecurrent is no longer applied, the wire 352 cools and returns to its moremalleable state. Once the wire cools below threshold, the tensive forceapplied can once again deform the wire into an open shape, releasing thepin.

Form and Operation of Particle-Filled Containers

FIGS. 13A-D show a first container embodiment, a master shape and avacuum cap, and further show a sequence of operations to create a shapedimpression, complementary to the master shape, in the surface of oneelastomeric membrane face of the container. Turning now to FIG. 3A, acontainer 5 is shown with a rigid container frame 10 and elastomeric topand bottom membranes 20 and 25, resting on a base 13 which separates thebottom membrane 25 from contact with any surface that the base 13 andthe container 5 rest on. The top membrane 20 is bonded to a perimeterframe 17 so as to have an air-tight interface between the containerframe 10 and the membrane 20. The container frame 10 is affixed to acontinuous vacuum-activated seal 30 which is bonded to the containerframe 10. The seal 30 is resilient and acts much like a suction cup tohold the perimeter frame 17 to the container frame 10. The bottommembrane 25 is bonded directly to rigid container frame 10 since themembrane 25 is not a working surface wearer to damage, in contrast tothe working surface of membrane 20 which is subject to damage. In oneembodiment, the bottom membrane 25 can be affixed by a perimeter frameand vacuum seal as described above. In yet another embodiment with morecomplexity, mechanical clamps and a pressure seal can be employed toaffix either top or bottom membranes. Tubes 40, 50 and 60 penetrate atoolbed or a container frame 10. The tube 40 communicates with a seal 30through an opening 45, and the seal 30 affixes the membrane 20 to thecontainer 5 by a vacuum (indicated by arrow 43) acting through the tube40. The vacuum seal 30 can be inactivated by introducing air through thetube 40, allowing the membrane 20 and the frame 10 to be removed inorder to insert or remove a volume of particles from the container 5, orto replace a damaged membrane 20 or internal screen element. The tube 50communicates with a main particle screen 55 which is overlaid with avolume of particles 80. Arrow 53 indicates the flow of liquid into theparticle volume through screens 55. The particle screens 55 serve tohold all particles in the container 5 while allowing liquid to flow inand out of the particle mass. There is a double layer construction ofboth screens 55 with the tubes 50 and 60 communicating between thelayers. The particles cannot penetrate the outer layers of the screensand so do not move into the tubes as air is evacuated or liquidextracted. Detail 57 of FIG. 7B-1 shows extensions of tubing 50penetrating into the center of the double-layered screens. Theextensions have perforations that enable distributed liquid flow alongthe length of the tube inside the screen. The tube 60 communicates witha rim evacuation screen element 65 which follows the entire inside upperperimeter of frame 10 and is likewise perforated along its length withinelement 65. Arrow 63 points outward to indicate deaerating vacuum forceacting on the container volume via the evacuation element.

Turning now to the top of FIG. 13A, a vacuum cap 90 is shown with acontinuous flexible or elastomeric membrane 95 bonded to anotherperimeter frame 100, the frame also having a continuous vacuum-activatedseal 105 bonded to the frame 100. The seal 105 is identical in designand function to the seal 30. The vacuum cap 90 has a tube 110, whichcommunicates with the vacuum seal through an opening 115, and a tube 125which in turn communicates with the underside of membrane 95 through aport 120.

A master shape 130 is shown resting on membrane 20. The master shapewill used to form a shaped impression in the membrane as described next.To prepare for the forming process, a membrane 20 is sealed to thecontainer; air is removed from the volume of particles as shown by arrow63; and liquid is introduced into the particle volume as shown by arrow53. Liquid flow is cut off when there is sufficient liquid to allowparticles to move in relation to adjacent particles as displacing forceis exerted on either the top or bottom membrane of the container.

FIG. 13C shows a side view of the container frame 10 with a vacuum cap70 resting over the master shape 130 prior to being sealed against themembrane perimeter frame 15 to which the membrane 20 is bonded, with themembrane affixed using the seal 30 to the container frame 10. The master130 is resting on the unformed surface of membrane 20 with the movableparticles between membranes 20 and 25.

FIG. 13D shows a cutaway view with the vacuum cap 90 affixed by the seal105 against the perimeter frame 15 by vacuum through the tube 110 asshown by an arrow 113. In addition the space between the vacuum capmembrane 95 and the top membrane 20 has been evacuated through the tube125 as shown by an arrow 127. The vacuum cap membrane 95 is pressed downagainst the master shape 130 and against the surface membrane 20 byatmospheric pressure which also acts opposedly against container bottommembrane 25. Liquid is then extracted by a pump or vacuum from theparticle volume through a tube (not shown) through the particle screen55, causing atmospheric forces acting on bottom membrane 25 to pack theparticles against top membrane 20 which is forced against the mastershape since air has been evacuated from between the vacuum cap membraneand top membrane 20. Any leakage of air into the container, which wouldadd atmospheric pressure back to the container and so reduce the packingforce on the particles, can be removed by continuing vacuum extractionof liquid through particle screens 55 or by vacuum extraction throughthe perimeter evacuation screen element 65.

When the master shape 130 is removed from the surface of the membrane20, an impressed shape 135 remains which is complementary to the shape130. The differential pressure on the container by vacuum extraction iscontinued, thereby maintaining opposed atmospheric forces that act tokeep membranes 20 and 25 pressed against the particles and soimmobilizing them to keep the impressed shape stabilized. In form theseal is a continuous channel with the legs angled outward. The channelhas a single opening and a vacuum and vent tube connected to it asdescribed with reference to FIG. 3A. The material of the seal isresilient since the legs will be pressed against a surface and mustconform to and seal against the surface. The legs are separated by asufficient distance that they will be pressed into contact with thesurface by atmospheric pressure with a greater force per unit area thanatmospheric pressure. In function, when the legs of the channel arepressed against a smooth surface and the vacuum introduced inside thechannel, the seal legs deform against the surface and the deformed areais substantially less than the area inside the channel. In experiments aratio of deformed area to inside area of 1 to 2 has been shown to bevery effective in sealing against a smooth surface if the durometer ofthe seal's elastomeric material is around 40. In operation the seal issimply placed against or gently pressed against a smooth air-impermeablesurface. A vacuum is introduced through the tube, extracting air fromwithin the seal and so enabling atmospheric pressure to force the sealagainst the surface. Any leakage from atmosphere outside the seal isscavenged by the vacuum and so does not enter the volume inside theperimeter of the seal even if a full vacuum is imposed on that volume.To release the seal air is introduced via the tube or a small blade canbe slipped between the seal and surface to break the internal vacuum.

The particles can be a reversible state-changeable mixture having aplurality of solid bodies and a carrier medium, with the carrier mediumfilling any voids or interstices between the bodies. Within the mixture,the solid bodies can be caused to transition from a formable state,preferably a near-liquid or fluent condition of mobility, to a stable,force-resisting condition through introduction and then extraction of aslight excess quantity of the carrier medium beyond that required tofill the interstices of the bodies when closely packed. In mostembodiments, the carrier medium is a liquid preferably excluding any airor other gases from the mixture, and most of the discussion will revolvearound such embodiments. However, some embodiments use a carrier mediumthat is a liquid-gas froth.

The mixture can be rapidly shifted from a formable (preferablynear-liquid or fluent) state to a stable force-resisting state and backagain to the formable state, through slightly altering the carrier-solidproportions of the mixture, and the system further provides methods andapparatus for using the mixture. Embodiments are characterized by one ormore of the following advantages: the ability to pressurize a mixtureand drive it against a complex surface as if it were a liquid; theability to create a “near-net” or extremely accurate representation of ashape due to the negligible volumetric change that accompanies a statechange; the ability to effect the state-change with a very small volumeof single-constituent transfer and with consequently small actuationdevices without the need for a vacuum pump, without chemical reactions,and with no need for thermal or electrical energy to be applied to themixture; the ability to greatly alter the volume of any elastic orotherwise dimensionally changeable container, envelope or chamberthrough the free-flowing transfer of the mixture from one container toanother; and the ability to tailor the mixture to satisfy a wide varietyof physical specifications in either the flowable or the stable state.

The mixture can be used in reformable molds or other shaping tools, andin reusable templates that capture the dimensions of impressed shapesfor transfer to a mold. The mixture can also be used in any product orshape that benefits from the incorporation of arbitrary reformability orprecise reconfigurability. The mixtures further provide usefulproperties for use in a wide range of shock-absorbing, leveling,protective and supportive elements or apparatus.

The mixture in its formable state may be loosely compared to quicksand,while the mixture in its stable state may resemble hard-packed sand oreven cement, with the transition being caused by the transfer of arelatively small amount of liquid. Hence the mixture, while in theformable state, includes enough liquid to fill the interstices betweenthe nested solid bodies, and an excess amount of liquid that is referredto as the transition liquid. In the stable state the transition liquidis absent and the bodies are completely packed or nested.

In preferred embodiments the solid bodies are uniform, generallyordered, and closely spaced, with the predominate mass of the bodiesclose-packed and touching. To create mobility, the transition liquid isintroduced in just-sufficient quantity to create a fluent condition byproviding a clearance between some of the bodies, which clearancepermits the introduction of at least two simultaneous slip planesbetween ordered masses of the bodies at any point in the mixture. Thebodies themselves separate freely from one another under movement of theliquid and without turbulent mixing, and shift relative to one anothergenerally in ordered bulk masses. The bodies should be of a density thatis close enough to that of the liquid to permit flow of the bodies alongwith the liquid, or should have a size or structure that facilitatesmovement of the bodies along with the liquid.

In an embodiment, the surface of the mixture while in the formable stateis first made to conform to a desired shape. The bodies in the mixtureare then caused to transition from the fluent condition to the stablecondition through extraction of the transition liquid. This extractionremoves the clearances required to provide slip-planes between orderedmasses of the solid bodies, thereby causing the bodies to make nested,packed, interlocking or otherwise stable consolidated contact. Themixture, now in the stable state, has a surface that conforms to thedesired shape.

The mixture can be used in molds, templates or other products throughholding the mixture in, or transferring quantities of the mixture whilein the fluent condition into and out of variable-contour orvariable-volume containers or chambers. The mixture can be stabilized byremoval of the transition liquid, which may cause an elastic membrane tobe pushed against the consolidated bodies by ambient pressure, or bytransition liquid removal that causes the solid bodies to pack togetherunder liquid tensile forces, thereby creating an ordered,deformation-resisting structure through surface friction or throughsurface adhesion of one body to another.

In certain embodiments, the mixture can be held inside a container ortransported into a container with a flexible, elastically deformable andstretchable wall. The process then extracts the transition liquid fromthe mixture so as to cause body-to-body contact and force-resistingstability through pressure external to the container acting on theconfined, ordered, abutting bodies. Transfer of fluent mixture into andout of the containers, or displacement of mixture within the containerscan be accomplished by pressure forces within the mixture, with theseforces being distributed uniformly throughout the mixture by the liquidcarrier medium.

This distribution of uniform pressure against the surface of each body,coupled with the clearance volume furnished by the transition liquid,assures that the bodies are not forced against one another while themixture is in the fluent condition. This elimination of body-to-bodycompression forces in turn prevents the bodies from sticking togetherand resisting displacement while the mixture is in the fluent condition.Pressure forces in the liquid can be exerted through pressing a shapeagainst an elastic, stretchable membrane that constitutes at least onesurface of a chamber substantially filled with the fluent mixture, orsuch forces within the liquid medium of the fluent mixture may beinduced by a two-way pump or other transfer system.

The bodies themselves may have various geometries and may be providedwithin a state-change mixture in one uniform type, or there may be twoor more types or sizes of bodies dispersed or layered within a mixture.For example spherical bodies of one size might have smaller bodiesfilling the interstices between the larger bodies, or a layer of shortfiber bodies might float above a layer of spherical bodies. Flake-likebodies can be also be used, in which case the flat faces of the bodiescan be pressed against one another to create a force-resisting bodymass. The flat faces provide many times the contact area of abuttingspheres, with accordingly higher friction or adhesion potential whenconsolidated against one another. If the flakes are in the form of alaminate that has one side heavier than the carrier medium and one sidelighter, and if the flakes are closely spaced and in a medium whichsuppresses turbulence and solid body tumbling, the bodies will tend tobe supported in, and to be consolidated in, an ordered parallelconfiguration. In this case, as with the spherical bodies, thetransition liquid quantity will be just sufficient to create shearmotion of body masses under low displacement forces.

Mixtures with more than one type or size of body can be used with thebodies either intermingled or layered separately, as by differingdensities or the inability of bodies of one layer to pass through bodiesin the adjacent layer. Bodies of different sizes or types may also beseparated from one another by flexible or extensible porous materials orfabrications that allow passage of liquids but not of the confinedbodies.

The degree of accuracy or irregularity on the surface of a stabilizedmass of the mixture is dependent upon the relationship between thefineness of the bodies and the dimensions to be captured, a coveringmembrane's thickness and conformability, and the size and degree ofregular packing order of a state-change mixture's solid bodies. If thebodies are very small compared to the contours of a shape that is to bereplicated, or if the interstices between larger bodies in the mixtureare filled by such smaller bodies, the mobile solid bodies of themixture will consolidate and assume a near-net shape relative to anyimpressed shape when the transition liquid is extracted from themixture.

In additional embodiments, the mixtures are stored external to one ormore molds, tools or fixtures, and are selectively introduced,stabilized and made fluent again in the tools. Formulas of the mixturesor solid bodies and liquids of the mixtures may be stored separately,and may be mixed or separated as required for effective operation ofseparate elements of a forming or tooling system.

In yet other embodiments, flexible elements containing state-changemixtures are used to capture exterior or interior contours of a shapeand to transfer the contours to other state-change elements. Throughsuch “templating” operations a negative of a shape or surface may beproduced and then a shape or surface identical to the first may beproduced by forming the surface of a mixture against the transfertemplate. Individual elements might also be used to transfer portions ofone shape to another shape and so create variations that combine thecontours of two or more shapes into a single shape.

In still other embodiments, several elastic, extensible elements filledwith state-change mixtures slide freely upon one another and relative tothe contained mixtures in order to conform to highly contoured shapes.These embodiments would be used when the elastic stretch of a singlemembrane element is not sufficient to capture details of a shape.

Further embodiments include methods of displacing fluent mixtures withinvariable-volume flat elastic envelopes by pressing the envelopes againstshapes with exterior air or liquid pressures, or pressing with physicalelements such as bundles of rods or fingers that slide relative to oneanother. The pressing force pressurizes the liquid carrier medium andcauses the envelopes to extend and conform to the shapes as thecontained fluent mixtures flow within the envelopes under the uniformlydistributed pressure forces within the liquid. Embodiments alsocontemplate the creation of hollow voids within a mixture-containingenvelope, with the impressed shape causing the collapse of the voids sothat the mixture need not be pumped into and out of a chamber to permitcapture of a shape.

Yet other embodiments include methods for creating a sculptablecondition in specific state-change mixtures through placing the mixturesin a quasi-stable state. The solid bodies are held in contact byextraction of a portion of the transition liquid, yet have sufficientlubricity or low contact friction to be displaced relative to oneanother by externally imposed forces. The bodies can be displaced intovoids created within a mass of the quasi-consolidated mixture, or can beprogressively displaced along the surface of the mixture from one regionof the mass to another. In some embodiments, properties of flow of themixture and the resistance to deformation of the abutted bodies arepredetermined so as to be a function of the imposed external forces, andso to be subject to variable control that allows intermediatequasi-stable, sculptable or displaceable conditions within or on thesurface of the bulk mixture.

State-change mixtures may also use solid bodies along with astate-changeable liquid carrier medium. The method for changing themixture from fluent to stable and back again is, as described above,through transfer of a small amount of excess liquid; however, themixture can be further solidified by changing the state of the carriermedium from liquid to solid.

In yet another embodiment, a state-change mixture is consolidated withina mold chamber and the liquid carrier or a second liquid component iscirculated while held to a pressure below ambient. Through heating andcooling of the circulating liquid, the mold itself can be heated orcooled.

Still another embodiment of the state-change mixture has solid bodiesthat are hollow and very light, and a carrier medium comprising aliquid-gas froth of similar density. The froth is destroyed whenextracted since the gas within it expands and separates from the liquidcomponent; then the froth is reconstituted from the liquid and gas andreintroduced into the body mass to recreate a fluent mixture. The liquidcomponent of the froth may be a solvatable (solvent-releasable) adhesivethat can be dried to hold the consolidated bodies together and thenre-dissolved by the frothed carrier medium. Very light bodies can alsosurrounded by a denser liquid, with the mixture likewise becoming fluentand then stabilized with transfer of a small quantity of transitionliquid; however, the tendency of the bodies to adhere together undercontact pressure is preferably countered, or liquid-like transfer of themixture, especially through small lines or passages, becomes difficultif not impossible.

In additional flat envelope embodiments internal and external elementsimprove their functioning as lightweight tooling and templates. Includedare methods to support these mixture-containing envelope structures,both internally with flexible reinforcements and externally with tubular‘foot’ structures that also contain state-change mixtures. The flatenvelopes may also be backed or supported by liquids or dry media withthe ability to capture precise impressions of a shape with the abilityto be switched from a liquid-like state to a firm state, or even to afully hardened state that resembles concrete yet can be returned to aformable condition.

The state change from liquid-like to solid-like properties within themixtures is effected by the transfer of a small amount of excess carriermedium, the transition liquid, into and out of the mixtures. When thetransition liquid is present, preferably in just-sufficient quantity tocreate the degree of support and clearance that provides for at leasttwo slip-planes, the solid bodies have a degree of mobility similar tothat of the liquid medium of the mixture. The slip-plane condition ofmobility can be generated through very small liquid pressuredifferentials or through externally imposed forces that displace thecarrier liquid and the supported bodies along with the liquid. Orderedbulk masses of the bodies can shift relative to other ordered masses atany point within a continuous volume of the mixture, and the location ofthe slip-planes can fluidly shift under any slight differential forcetransferred from one body to another. It is preferred to preventfrictional contact between bodies during such force transfer by havingthe liquid medium of the mixture furnish a viscous or ‘streaming’resistance to contact, and also for the medium to furnish a degree ofbody-surface lubrication so that light body contacts do not createfriction between bodies.

Lubricity under high contact forces, as is required for many lubricatingmedia, is not necessary within the mixtures since the bodies are ineffect free-floating during flow, with any imposed liquid pressureforces being uniformly distributed against the surface of each body. Forexample a nearly ideal aqueous liquid medium can be formed by dissolvinga small quantity of a soluble long-chain polymer such as polyethyleneoxide into water. The medium carries solid bodies of a similar densitywithout turbulence and friction-producing contact, allows the bodies tomake non-lubricated surface contact when the medium is extracted, andcauses the bodies to readily separate when the transition liquid isreintroduced.

When the transition liquid is extracted so that the solid bodies are ina stable configuration with ordered, packed and consolidated contact,the degree of resistance to externally imposed forces depends on suchtailorable, engineered physical properties as body shape, bodyelasticity and compressibility, body surface properties of roughness,smoothness or natural molecular adhesion, residual adhesiveness orlubricity of the liquid medium on the contacting surfaces, surfacetension of the medium, and variations of liquid medium or bodyproperties with changes of temperature or pressure; alteration of theresistance properties through replacement of the first liquid with asecond liquid medium, rinsing of the bodies and the first medium with asecond or sequential liquid media, vapors or gaseous fluids; and anyother engineered variations in the bodies and first liquid medium, andin other sequential introductions of various fluids into the mixtures orthrough the consolidated bodies. Any adhesive or clinging contactbetween the bodies is preferably relieved through polar molecular actionof the first liquid medium, or through an intermediary treatment withother liquids or fluids prior to reintroduction of the first liquidmedium.

The container works with quickly reversible state-change mixtures whichcan be rapidly shifted from a near-liquid or fluent state to a stableforce-resisting state through slightly altering the liquid-solidproportions, and the system further provides methods and apparatus forutilizing the mixtures. Embodiments are characterized by one or more ofthe following advantages: the ability to pressurize a mixture and driveit against a complex surface as if it were a liquid; the ability tocreate a “near-net” or extremely accurate representation of a shape dueto the negligible volumetric change which accompanies a state change;the ability to effect the state-change with a very small volume ofsingle-constituent transfer and with consequently small actuationdevices, with a low-energy mechanical actuation, and without requiring avacuum pump, thermal, chemical or electrical energy to be applied to themixture; the ability to greatly alter the volume of any elastic orotherwise dimensionally changeable container, envelope or chamberthrough the free-flowing transfer of the nearly solid mixtures from onecontainer to another; and the ability to tailor the mixtures to satisfya wide variety of physical specifications in either the flowable or thestable state.

The mixtures can be employed in reformable molds or other shaping tools,and in reusable templates which capture the dimensions of impressedshapes for transfer to a mold. The mixtures can also be used in anyproduct or shape which benefits from the incorporation of arbitrarilyreformability or precise reconfigurability. The mixtures further provideuseful properties for but are not limited to application in a wide rangeof shock-absorbing, leveling, protective and supportive apparatus.

It can be appreciated that there are numerous variations of containersand varied combinations of containers which can be employed either toform a surface which is complementary to the exterior surface of amaster shape in part or in whole, or to form a surface or surfacescomplementary to the interior contours of a hollow master shape ormaster cavity. For instance more than one container of the first type(rigid frame) or second type (flexible-edge) can be employed to form acontinuous surface complementary to a master shape's surface, with theelastomeric membranes of the containers either overlapping or beingabutted together. Containers of the second type may also have a membraneand particle configuration that allows two or more of the containers tobe “tiled” together to form a continuous surface of particle-backedmembranes. Likewise two or more containers of the third type can beemployed together to form a shape complementary to the interior of amaster cavity. More details on the reformable manufacturing aredisclosed in commonly owned patents to Jacobson et al including U.S.Pat. No. 6,398,992 and Pub. No. 20050035477 and 20070187855, thecontents of which are incorporated by reference.

In the context of shoe manufacturing, a computing device may be used todetermine operations of various shoe-manufacturing tools. For example, acomputing device may be used to control a part-pickup tool or a conveyorthat transfers shoe parts from one location to another. In addition, acomputing device may be used to control a part-attachment device thatattaches (e.g., welds, adheres, stitches, etc.) one shoe part to anothershoe part.

1. A method to shape a reformable material, comprising:

generating a 3D model of an object;

adjusting the 3D model to optimize a parameter or treat a sportenthusiast;

forming a reformable master shape from the adjusted 3D model;

holding a volume of particles inside a container having a firstelastomeric membrane surface;

infusing the volume with a liquid to mobilize the volume of particles;and

pressing the reformable master shape into the membrane with atmosphericpressure.

2. The method of claim 1, comprising extracting the liquid through oneor more screen elements placed proximal to the volume of particles.

3. The method of claim 1, wherein the atmospheric pressure holds theparticles against the elastomeric membrane when the master shape isremoved from the membrane.

4. The method of claim 1, comprising heating and driving liquid from theparticle volume.

5. The method of claim 1, comprising providing a binding adhesive tolock the particles into a force-resisting mass.

6. The method of claim 1, comprising pressing a complementary shape intothe master shape in the membrane.

7. The method of claim 1, wherein the container comprises a rigidoutside frame with top and bottom elastomeric membranes, comprisingpressing the master shape against the elastomeric membrane.

8. The method of claim 7, wherein the pressing comprises

applying a flexible vacuum cap sealed over the shape and against theelastomeric membrane surface;

evacuating air from a space formed between the membrane and the vacuumcap;

extracting liquid from the volume; and

pressing the particles within the container with atmospheric forceacting in opposed directions against the vacuum cap and the bottomsurface membrane.

9. The method of claim 7, comprising introducing air into the vacuumcap, and removing the cap and the master shape from the surface of theelastomeric membrane.

10. The method of claim 1, wherein the container is formed against themaster shape.

11. The method of claim 10, comprising performing a liquid infusion, apressing action under atmospheric pressure, and a liquid extraction.

12. The method of claim 10, comprising

placing the master shape on an air-impermeable surface;

placing a membrane of the container over the shape; and

placing a vacuum cap or a vacuum-bagging film over the container to formthe elastomeric membrane against the master shape.

13. The method of claim 1, comprising applying an envelope containing amass of particles and with a vacuum seal on its perimeter to extract airfrom a space between the master shape and the envelope.

14. The method of claim 1, comprising placing the master shape on theelastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape.

15. The method of claim 14, wherein the second container fits inside theframe of the first container and a vacuum cap is placed over and sealedoutside the second container against the surface membrane of the firstcontainer.

16. The method of claim 14, comprising evacuating the volume under thevacuum cap and pressing the master shape between the elastomeric sidesof the first and second containers.

17. The method of claim 16, comprising extracting the liquid to pressthe two volumes of particles together and against the membranessurrounding the contained shape.

18. The method of claim 14, comprising venting the vacuum cap with airand removing the vacuum cap and the first container; and removing theshape from the membrane of the second container, placing the firstcontainer adjacent with the second container; and forming a closed,shaped cavity complementary to the surface of the master shape used toform the cavity.

19. The method of claim 14, comprising pressing two identical containersof either the first or the second container around a master shapewithout using the vacuum cap.

20. The method of claim 19, wherein the containers are joined and sealedby either a seal mounted on one or both of the containers or by sealsmounted on a seal ring fitted between the two containers.

21. The method of claim 1, comprising deaerating the volume ofparticles.

22. A method to form an object, comprising:

generating a 3D model of an object;

adjusting the 3D model to optimize a parameter or treat a sportenthusiast;

forming a reformable master shape from the adjusted 3D model;

infusing a liquid into a container having a first elastomeric membranesurface;

pressing the master shape into the membrane with atmospheric pressure;and

shaping a reformable material into the object according to the mastershape.

23. The method of claim 22, comprising extracting the liquid.

24. The method of claim 22, comprising deaerating the volume ofparticles;

25. The method of claim 22, comprising extracting the liquid through oneor more screen elements placed proximal to the volume of particles.

26. The method of claim 22, comprising heating and driving liquid fromthe particle volume.

27. The method of claim 22, comprising providing a residue of a bindingadhesive to lock the particles into a continuous force-resisting mass.

28. The method of claim 22, comprising impressing a complementary shapeto the master shape in the membrane.

29. The method of claim 22, wherein the container comprises a rigidoutside frame and top and bottom elastomeric membranes facing the topand bottom surfaces of the container, comprising pressing the mastershape against the top elastomeric membrane of the container withatmospheric pressure.

30. The method of claim 29, wherein the pressing comprises

applying a flexible vacuum cap sealed over the shape and against thecontainer top surface membrane;

evacuating air from a space between the top surface membrane and thevacuum cap;

extracting liquid from the volume; and

pressing the particles within the container with atmospheric forceacting in opposed directions against the vacuum cap and the bottomsurface membrane.

31. The method of claim 29, comprising introducing air into the vacuumcap, and removing the cap and the master shape from the formed surfaceof the elastomeric membrane.

32. The method of claim 22, comprising forming the container against themaster shape.

34. The method of claim 32, comprising:

placing the master shape on an air-impermeable surface;

placing a membrane of the container over the shape; and

placing a vacuum cap or a vacuum-bagging film over the container toeffect forming of the elastomeric membrane against the master shape.

35. The method of claim 22, comprising applying an envelope containing amass of particles and with a vacuum seal on the envelope perimeter toextract air from the master shape and the envelope.

36. The method of claim 22, comprising placing the master shape on thetop elastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape.

37. The method of claim 36, wherein the second container fits inside theframe of the first container and a vacuum cap is placed over and sealedoutside the second container against the surface membrane of the firstcontainer.

38. The method of claim 36, comprising evacuating the volume under thevacuum cap and pressing the master shape between the elastomeric sidesof the first and second containers.

39. The method of claim 38, comprising extracting the liquid to pressthe two volumes of particles together and against the membranes.

40. The method of claim 36, wherein the vacuum cap is vented with airand removed; the top container is removed; and the shape is removed fromthe membrane of the bottom container, comprising placing the topcontainer over the bottom container; and forming a closed, shaped cavitycomplementary to the surface of the master shape used to form thecavity.

41. The method of claim 36, wherein the first and second containers areidentical, comprising pressing the containers around a master shapewithout using the vacuum cap.

42. The method of claim 41, wherein the containers are joined and sealedby one of: a seal mounted on one or both containers, a seal mounted on aseal ring fitted between the two containers.

1. A method to form an object, comprising:

infusing a liquid into a container having a frame with first and secondelastomeric membranes; a first port to deaerate the volume of particles;and a second port to infuse the volume with a liquid for mobilizing thevolume of particles;

generating a 3D model of an object;

adjusting the 3D model to optimize a parameter or treat a sportenthusiast;

forming a reformable master shape from the adjusted 3D model;

pressing the master shape into the membrane with atmospheric pressure;and

shaping a reformable material into the object according to the mastershape.

2. The method of claim 1, comprising extracting the liquid.

3. The method of claim 1, comprising deaerating the volume of particles;

4. The method of claim 1, comprising extracting the liquid through oneor more screen elements placed proximal to the volume of particles.

5. The method of claim 1, comprising heating and driving liquid from theparticle volume.

6. The method of claim 1, comprising providing a binding adhesive tolock the particles into a force-resisting mass.

7. The method of claim 1, comprising pressing a shape complementary tothe master shape in the membrane.

8. The method of claim 1, wherein the container comprises a rigidoutside frame and top and bottom elastomeric membranes facing the topand bottom surfaces of the container, comprising pressing the mastershape against the top elastomeric membrane of the container withatmospheric pressure.

9. The method of claim 8, wherein the pressing comprises

applying a flexible vacuum cap sealed over the shape and against thecontainer's top surface membrane;

evacuating air from a space between the top membrane and the vacuum cap;

extracting liquid from the volume; and

pressing the particles within the container with atmospheric forceacting in opposed directions against the vacuum cap and the bottomsurface membrane.

10. The method of claim 8, comprising introducing air into the vacuumcap, and removing the cap and the master shape from the formed surfaceof the elastomeric membrane.

11. The method of claim 1, wherein the container is formed against themaster shape.

12. The method of claim 11, comprising:

placing the master shape on an air-impermeable surface;

placing a membrane of the container over the shape; and

placing a vacuum cap or a vacuum-bagging film over the container toeffect forming of the elastomeric membrane against the master shape.

13. The method of claim 1, comprising applying an envelope containing amass of particles and with a vacuum seal on a perimeter to extract airfrom between the master shape and the envelope.

14. The method of claim 1, comprising placing the master shape on thetop elastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape.

15. The method of claim 14, wherein the second container fits inside theframe of the first container and a vacuum cap is positioned and sealedoutside the second container against the surface membrane of the firstcontainer.

16. The method of claim 14, comprising evacuating the volume under thevacuum cap and pressing the master shape between the elastomeric sidesof the first and second containers.

17. The method of claim 16, comprising extracting the liquid to pressthe two volumes of particles together and against the membranessurrounding the shape.

18. The method of claim 14, comprising venting the vacuum cap with airand removing the first container; removing the shape from the membraneof the second container, placing the first container adjacent to thesecond container; and forming a closed, shaped cavity complementary tothe surface of the master shape.

19. The method of claim 14, comprising pressing two identical containersof either the first or the second container around a master shapewithout using the vacuum cap.

20. The method of claim 19, wherein the containers are joined and sealedby either a seal mounted on one or both of the containers or by sealsmounted on a seal ring fitted between the two containers.

21. The method of claim 1, comprising extracting the liquid prior toremoving the master shape from the shaped reformable material.

22. The method of claim 1, comprising solidifying the liquid within theshaped reformable material.

23. The method of claim 1, comprising withdrawing the liquid to leave aresidue of liquid on the shaped reformable material; and solidifying theresidue.

24. The method of claim 1, comprising preforming a material surface overthe master shape.

25. The method of claim 24, wherein the preforming comprises one of:thermoforming, additive processing.

26. The method of claim 1, wherein the container walls comprise air andliquid impermeable walls.

27. The method of claim 26, comprising providing an inelastic formablesurface conforming to the master shape surface.

28. The method of claim 1, comprising forming a surface over the mastershape.

29. The method of claim 1, comprising pressing the shaped materialsurface against the volume of particles without deforming the shapedmaterial surface.

30. The method of claim 1, comprising:

-   -   providing a release surface to the master shape;    -   pressing the master shape against the volume of particles to        form the object with the release surface; and    -   removing the object using the release surface.

31. The method of claim 30, wherein providing the release surfacecomprises providing an area around the master shape with a surfaceelement covering the reformable material surface not overlaid with themaster shape surface;

1. An apparatus to form an object in accordance with a master shape,comprising:

a computer actuated 3D shape generator to render the master shape;

a container to hold a volume of particles, said container having a firstelastomeric membrane surface; a first port to deaerate the volume ofparticles; and a second port to infuse the volume with a liquid formobilizing the volume of particles; and

a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to theshape generator's master shape.

2. The apparatus of claim 1, comprising one or more screen elementsplaced proximal to the volume of particles to extract the liquid.

3. The apparatus of claim 1, wherein atmospheric pressure holds thevolume of particles in place against the elastomeric membrane when themaster shape is removed from the membrane.

4. The apparatus of claim 1, comprising a heater to heat and driveliquid from the particle volume.

6. The apparatus of claim 1, wherein the container comprises a rigidoutside frame and top and bottom elastomeric membranes facing the topand bottom surfaces of the container, and wherein the master shape ispressed against the top elastomeric membrane of the container byatmospheric pressure.

7. The apparatus of claim 6, comprising:

a flexible vacuum cap sealed over the shape and against the container'stop surface membrane;

a third port to evacuate air from a space between the top membrane andthe vacuum cap; and

wherein the particles within the container are pressed with atmosphericforce acting in opposed directions against the vacuum cap and the bottomsurface membrane.

8. The apparatus of claim 6, wherein air is introduced into the vacuumcap, and wherein the cap and the master shape are removed from a surfaceof the elastomeric membrane.

9. The apparatus of claim 8, wherein the master shape is placed betweenan air-impermeable surface and the membrane of the container and whereina vacuum cap or a vacuum-bagging film is placed over the container toform the elastomeric membrane against the master shape.

10. The apparatus of claim 1, comprising an envelope containing a massof particles and with a vacuum seal on its perimeter to extract airbetween the master shape and the envelope.

11. The apparatus of claim 1, comprising placing the master shape on thetop elastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape.

12. The apparatus of claim 11, wherein the second container fits insidethe frame of the first container and a vacuum cap is placed over andsealed outside the second container against the surface membrane of thefirst container.

13. The apparatus of claim 11, comprising a vacuum pump to evacuate thevolume under the vacuum cap and press the master shape between theelastomeric sides of the first and second containers.

14. The apparatus of claim 11, comprising a pump to extract the liquidto press the two volumes of particles together and against the membranessurrounding the contained shape.

15. The apparatus of claim 14, wherein the vacuum cap is vented with airand removed; the first container is removed; and the shape is removedfrom the membrane of the second container and wherein the firstcontainer is placed adjacent the second container to form a closed,shaped cavity complementary to the surface of the master shape used toform the cavity.

16. The apparatus of claim 14, wherein the first and second containersare identical and wherein the containers are pressed around a mastershape without using the vacuum cap.

17. The apparatus of claim 14, wherein the containers are joined andsealed by either a seal mounted on one or both of the containers or byseals mounted on a seal ring fitted between the containers.

18. The apparatus of claim 14, comprising a seal ring to channel vacuumor air pressure between the containers and to hold the master shape in apredetermined orientation and position between the opposed containers.

19. The apparatus of claim 1, comprising an expander within thecontainer to press the particulate material against cavity walls of thecontainer.

20. The apparatus of claim 1, comprising

a second container cooperating with the first container to form acomplementary cavity from the master shape; and

a third container placed in the complementary cavity to replicate themaster shape.

21. The apparatus of claim 1, wherein the container comprises a frame.

22. The apparatus of claim 21, wherein the frame comprises one of: arigid frame, a flexible-edge frame.

23. The apparatus of claim 21, wherein the frame comprises a continuoussurface complementary to a master shape's surface.

24. The apparatus of claim 1, comprising a second elastomeric membrane,wherein the elastomeric membranes overlap each other.

25. The apparatus of claim 1, comprising a second elastomeric membrane,wherein the elastomeric membranes abut each other.

26. The apparatus of claim 1, comprising one or more additionalcontainers each having a membrane coupled to the container to form acontinuous surface of membranes.

27. The apparatus of claim 1, comprising one or more additionalcontainers to form a shape complementary to the interior of a mastercavity.

1. An apparatus to form an object in accordance with a master shape,comprising:

a computer actuated 3D shape generator to render the master shape;

a container to hold a volume of particles, said container having a framewith first and second elastomeric membranes; a first port to deaeratethe volume of particles; and a second port to infuse the volume with aliquid for mobilizing the volume of particles; and

a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape.

2. The apparatus of claim 1, wherein the second membrane is bonded tothe frame.

3. The apparatus of claim 1, wherein the first membrane is coupled to aseal.

4. The apparatus of claim 1, comprising a clamp to secure at least onemembrane to the frame.

5. The apparatus of claim 1, comprising one or more ports on the frame.

6 The apparatus of claim 1, comprising liquid, evacuation, andvacuum-activated seal tubes coupled to the frame.

7. The apparatus of claim 1, comprising a rim evacuation screen elementpositioned in the frame.

8. The apparatus of claim 1, wherein the frame is one of: a rigid frame,a flexible frame.

9. The apparatus of claim 1, comprising a vacuum activated seal on theframe.

10. The apparatus of claim 1, comprising a tube to evacuate and fill thecontainer.

11. The apparatus of claim 1, comprising double layer screens havingfeed elements to distribute and extract liquid through the volume ofparticles.

12. The apparatus of claim 1, comprising one or more screens conformallycoupled to the master shape.

13. The apparatus of claim 1, comprising one or more internal screensmounted with the particles flowing on both sides of each internalscreen.

14. The apparatus of claim 1, wherein the frame is flexible, comprisingone or more containers joined together around the master shape.

15. The apparatus of claim 1, wherein the frame is flexible, comprisingone or more containers joined by vacuum seals.

16. The apparatus of claim 1, comprising one or more feed tubes coupledto an interior element inside the membrane.

17. The apparatus of claim 1, comprising a flexible spine element withinan interior cavity of the container.

18. The apparatus of claim 1, comprising one or more reinforcementfibers.

19. The apparatus of claim 18, wherein the fibers are distributed inbundles within the volume of particles.

20. The apparatus of claim 1, comprising an air pump to provide internalpressurization.

21. The apparatus of claim 1, comprising a vacuum source to provide avacuum between a cavity in the container and the container.

22. The apparatus of claim 1, comprising an air pump and a vacuum sourceto alternately pressurize and vent the container to distribute thevolume of particles therein.

23. The apparatus of claim 1, comprising a seal ring.

24. The apparatus of claim 23, wherein the seal rings are mounted.

25. The apparatus of claim 23, wherein the seal comprises a vacuumactivated seal.

26. The apparatus of claim 23, comprising a second container joined withthe container and wherein a vacuum is formed in an interior of thejoined containers.

27. The apparatus of claim 26, wherein the master shape is mounted onthe seal ring.

28. The apparatus of claim 26, comprising one or more flanges mounted tocontrol a mating line between opposed membranes of containers.

29. The apparatus of claim 1, comprising a second container positionedwithin a cavity formed by an outside container.

30. The apparatus of claim 1, comprising a vacuum cap.

31. The apparatus of claim 30, comprising a vacuum seal coupled to thevacuum cap.

32. The apparatus of claim 30, comprising a vacuum tube penetratingthrough the membrane.

33. The apparatus of claim 1, comprising a vacuum cap with mountedcontainer 245 in place of the membrane

34. The apparatus of claim 1, comprising one or more screen elementsplaced proximal to the volume of particles to extract the liquid.

35. The apparatus of claim 1, wherein atmospheric pressure holds thevolume of particles in place against the elastomeric membrane when themaster shape is removed from the membrane.

36. The apparatus of claim 1, comprising a heater to heat and driveliquid from the particle volume.

37. The apparatus of claim 1, wherein the container comprises a rigidoutside frame and top and bottom elastomeric membranes facing the topand bottom surfaces of the container, and wherein the master shape ispressed against the top elastomeric membrane of the container withatmospheric pressure.

38. The apparatus of claim 1, comprising an envelope containing a massof particles and with a vacuum seal on its perimeter to extract air frombetween the master shape and the envelope.

39. The apparatus of claim 1, comprising placing the master shape on thetop elastomeric surface of a first rigid-framed container and placing amembrane surface of a second container over the master shape.

40. The apparatus of claim 1, comprising an expander within thecontainer to press the particulate material against cavity walls of thecontainer.

41. The apparatus of claim 1, comprising

a second container cooperating with the first container to form acomplementary cavity from the master shape; and

a third container placed in the complementary cavity to replicate themaster shape.

42. The apparatus of claim 1, comprising a second elastomeric membrane,wherein the elastomeric membranes overlap or abut each other.

43. The apparatus of claim 1, comprising one or more additionalcontainers each having a membrane coupled to the container to form acontinuous surface of membranes.

44. The apparatus of claim 1, comprising one or more additionalcontainers to form a shape complementary to the interior of a mastercavity.

1. A base station to form an object in accordance with a master shape,comprising:

a computer actuated 3D shape generator to render the master shape;

a liquid receiver;

a vacuum source to evacuate air from the liquid receiver;

an air compressor to generate pressurized air; and

a controller coupled to the liquid receiver, the vacuum source and theair compressor to form the object.

2. The base station of claim 1, comprising one or more tubes to providevacuum and to control the flow of liquids to and from the receiver.

3. The base station of claim 1, comprising one or more valves coupled tothe controller.

4. The base station of claim 1, comprising one or more sensors coupledto the controller.

5. The base station of claim 1, comprising an electrical power supply tooperate valves, sensors, the vacuum pump and the air compressor.

6. The base station of claim 1, wherein the controller comprises amenu-driven process controller to operate the base station.

7. The base station of claim 1, comprising a heater to vaporize andexpel liquid from the receiver and to heat a reformable material.

8. The base station of claim 7, wherein the reformable material createscontours of the master shape.

9. The base station of claim 7, wherein the reformable material ismolded against a complementary surface of an elastomeric membrane.

10. The base station of claim 7, wherein the liquid contains a solublebinder.

11. The base station of claim 10, wherein the binder remains on a shapedvolume of particles.

12. The base station of claim 10, wherein the binder locks a shapedvolume of particles in place after the liquid is removed.

13. The base station of claim 7, comprising wherein the heater comprisesone of: a radiant heater, a convective air heater, a microwave heater, aradio-frequency heater, an inductive heater.

14. The base station of claim 7, comprising the heater comprises one ormore heating elements within the container.

15. The base station of claim 7, comprising the heater is controlled bythe controller.

16. The base station of claim 1, comprising:

a container to hold a volume of particles, said container having a framewith first and second elastomeric membranes; a first port to deaeratethe volume of particles; and a second port to infuse the volume with aliquid for mobilizing the volume of particles; and

a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape.

17. The base station of claim 1, comprising

a container to hold a volume of particles, said container having a firstelastomeric membrane surface; a first port to deaerate the volume ofparticles; and a second port to infuse the volume with a liquid formobilizing the volume of particles; and

a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape.

18. The base station of claim 17, wherein the container comprises arigid outside frame and top and bottom elastomeric membranes facing thetop and bottom surfaces of the container, and wherein the master shapeis pressed against the top elastomeric membrane of the container byatmospheric pressure.

19. The base station of claim 18, comprising:

a flexible vacuum cap sealed over the shape and against the container'stop membrane;

a third port to evacuate air from a space between the top membrane andthe vacuum cap; and

a fourth port to extract liquid from the volume;

wherein the particles within the container are pressed by atmosphericforce acting in opposed directions against the vacuum cap and a bottommembrane.

20. The base station of claim 18, wherein the master shape is placedbetween an air-impermeable surface and the membrane of the container andwherein a vacuum cap or a vacuum-bagging film is placed over thecontainer to form the elastomeric membrane against the master shape.

21. The base station of claim 1, wherein the vacuum pump comprises oneof: a mechanical pump, an air driven pump.

22. The base station of claim 1, wherein the vacuum comprises a Venturipump.

23. The base station of claim 1, comprising a second vacuum pump.

24. The base station of claim 23, comprising isolating valves coupled tothe vacuum pumps.

25. The base station of claim 1, comprising a regulator and one or morevalves coupled to the vacuum pump to pressurize a liquid tank.

26. The base station of claim 25, comprising a vent valve coupled to theliquid tank to cycle from a vacuum source to a pressure source.

27. The base station of claim 25, comprising a three-way valve to routeair and vacuum to the liquid tank.

28. The base station of claim 25, comprising a filter coupled to theliquid tank to prevent particulate carryover.

29. The base station of claim 1, comprising an air-liquid separator.

30. The base station of claim 1, comprising a level indicator.

31. The base station of claim 1, comprising a vacuum sensor coupled tothe controller for process control.

32. The base station of claim 1, comprising a heat exchanger coupled tothe container to condense vapor.

33. The base station of claim 1, comprising one or more outsidecontainers in combination forming a cavity and an inside container inthe formed cavity.

34. The base station of claim 1, comprising a slurry transfer tankcoupled to the container.

35. The base station of claim 1, comprising one or more containerscoupled to the container.

36. The base station of claim 35, wherein the containers are mated witha seal ring.

1. A method to shape a reformable material, comprising:

generating a 3D model of an object;

adjusting the 3D model to optimize a parameter or treat a wearer;

forming a reformable master shape from the adjusted 3D model;

holding a volume of particles inside a container having a firstelastomeric membrane surface; and infusing the volume of particles witha liquid;

agitating the liquid to provide one or more surges of liquid to mobilizethe volume of particles; and

pressing the master shape into the membrane with atmospheric pressure.

2. The method of claim 1, comprising providing locally distributedsurges.

3. The method of claim 1, comprising providing globally distributedsurges.

4. The method of claim 1, wherein the one or more surges exertdifferential liquid forces on particles to displace them relative to oneanother and facilitate their movement into a closely-packed volume.

5. The method of claim 1, comprising providing a differential pressurebetween a master shape side and a liquid-particle side of the membrane.

6. The method of claim 1, comprising decreasing the pressure between avacuum cap and the membrane to move the membrane in a first direction.

7. The method of claim 1, comprising increasing the pressure between avacuum cap and the membrane to move the membrane in a second direction.

8. The method of claim 6, wherein membrane is free to move relative tomaster shape.

9. The method of claim 1, wherein the liquid moves through particlestoward membrane, and wherein the particles move toward the membrane.

10. The method of claim 1, comprising removing excess liquid and leavingparticles against the membrane.

11. The method of claim 1, comprising evacuating air from space betweenthe membranes.

12. The method of claim 1, comprising packing the particles against themembranes and the master shape.

13. The method of claim 1, comprising extracting the liquid with thevacuum cap and membrane pressed against the master shape to pack theparticles against the membranes and the master shape.

14. The method of claim 1, wherein the agitating comprises pulsing theliquid.

15. The method of claim 1, wherein the agitating comprises vibrating theliquid.

16. The method of claim 15, comprising adjusting a vibration frequencyto displace one particle relative to another to keep the particlesmoving freely in relation to one another.

17. The method of claim 1, wherein amplitude of liquid pulsation isproximally equal to a diameter of the particles.

18. The method of claim 1, comprising generating a first surge of liquidtowards a desired transport direction.

19. The method of claim 18, comprising generating a second surge smallerthan the first surge in an opposite direction to the transportdirection.

20. The method of claim 1, comprising agitating the liquid to minimizeblockage.

21. The method of claim 1, comprising maintaining the volume of thecontainer constant and completely filled to force the particles againstthe master shape.

22. The method of claim 21, comprising:

extracting transitional liquid from the container; and

adding new liquid equal in volume of the transition liquid.

1. A shape-reformable composition, comprising:

a carrier medium having a carrier density; and

a plurality of solid bodies having a density substantially similar tothe carrier density, said solid bodies being transitionable from aformable state to a three dimensional solid shape.

2. The composition of claim 1, wherein the carrier medium fills voids orinterstices between the solid bodies.

3. The composition of claim 1, wherein the voids or interstices are freeof air or gas bubbles.

4. The composition of claim 1, wherein the solid bodies comprise anear-liquid or fluent mobility during the formable state.

5. The composition of claim 1, wherein the solid bodies transition tothe solid shape through an introduction and an extraction of apredetermined amount of the carrier medium.

6. The composition of claim 1, wherein solid bodies are positioned in acontainer having a first elastomeric membrane surface.

7. The composition of claim 6, wherein liquid is introduced to mobilizethe volume of particles.

8. The composition of claim 6, wherein a master shape is pressed intothe membrane with atmospheric pressure.

9. The composition of claim 1, wherein the solid shape comprises astable, force-resisting shape.

10. The composition of claim 1, wherein the solid bodies and carriermedium form a reversible state-changeable mixture

11. The composition of claim 1, wherein the carrier medium comprises aliquid.

12. The composition of claim 1, wherein the carrier medium comprises agaseous froth.

13. The composition of claim 1, wherein the shape comprises a reformablemold.

14. The composition of claim 1, comprising a reusable template tocapture dimensions of impressed shapes for transfer to a mold.

15. The composition of claim 1, comprising a binder to bind the solidbodies.

16. The composition of claim 15, wherein the binder comprises one of: aTEOS binder, an ethanol based material, a eutectic metal, and a fiber.

17. The composition of claim 15, wherein the binder comprises athermally conductive particle.

18. The composition of claim 15, wherein the binder comprises one ormore electrically heated particles.

19. The composition of claim 18, wherein the particle comprise aresistive coating for resistive heating.

20. The composition of claim 15, wherein the binder comprises anelastomeric binder.

21. The composition of claim 15, wherein the binder is hardened withintroduced liquid or gas after forming.

22. The composition of claim 15, wherein the binder is hardened with hotair through the particles.

23. The composition of claim 22, wherein the binder is formed at apressure above atmospheric pressure.

24. The composition of claim 15, wherein a pH value for the binder isincreased or decreased.

25. The composition of claim 1, comprising a surface coating on shapedsolid bodies to add smoothness, toughness, and better release propertiesfor the composition.

1. A vacuum activated seal for a container, comprising:

a channel having one or more legs angled outwardly and spaced apart,said legs having contact areas adapted to be pressed against a surfacewith a greater force per unit area than atmospheric pressure; saidchannel having an opening therein; and

a tube penetrating from the outside of the channel to the inside of thechannel through the opening.

2. The seal of claim 1, wherein the channel is mounted as a continuousring.

3. The seal of claim 2, wherein the ring is positioned on the containerperimeter.

4. The seal of claim 1, wherein the ring is positioned on a flange.

5. The seal of claim 1, wherein the legs are forced against the surfaceby atmospheric pressure when the channel is evacuated.

6. The seal of claim 1, wherein a total unit area on the back of thechannel exceeds the total unit area of the leg area in contact with thesurface.

7. The seal of claim 1, wherein the seal is used to enclose a volumebetween two air-impermeable elements.

8. The seal of claim 7, wherein the seal prevents leakage from theoutside to the inside of the volume as a contact pressure exceedsatmospheric pressure.

8A. The seal of claim 8, wherein the contact pressure comprises applyinga vacuum on the volume.

9. The seal of claim 1, wherein the seal scavenges air from the outsideif a leak occurs through imperfections in the seal or the surface.

10. The seal of claim 1, wherein the surface of the seal is placedagainst or pressed down against a smooth air-impermeable surface.

10. The seal of claim 1, wherein the surface comprises one of: aflange-mounted membrane, a seal ring, a second seal.

11 The seal of claim 1, wherein a vacuum is introduced through the tubeto extract air from the inside of the seal.

12. The seal of claim 1, wherein atmospheric pressure acting on the backof the channel presses the legs of the channel against the surface.

13. The seal of claim 1, wherein the channel comprises a resilientmaterial.

14. The seal of claim 1, wherein the channel comprises an elastomericmaterial.

15. The seal of claim 1, wherein the channel comprises rubber.

16. The seal of claim 1, comprising a container to hold a volume ofparticles, said container having a first elastomeric membrane surface; afirst port to deaerate the volume of particles; and a second port toinfuse the volume with a liquid for mobilizing the volume of particles.

17. The seal of claim 16, comprising a press coupled to the container tomove the master shape into the membrane to shape a reformable materialinto the object according to the master shape.

18. The seal of claim 16, comprising one or more screen elements placedproximal to the volume of particles to extract the liquid.

19. The seal of claim 16, wherein atmospheric pressure holds the volumeof particles in place against the elastomeric membrane when the mastershape is removed from the membrane.

20. An apparatus to form an object in accordance with a master shape,comprising:

a container to hold a volume of particles, said container having a firstelastomeric membrane surface; a first port to deaerate the volume ofparticles; and a second port to infuse the volume with a liquid formobilizing the volume of particles; and a vacuum activated seal for thecontainer, including: a channel having one or more legs angled outwardlyand spaced apart, said legs having contact areas adapted to be pressedagainst a surface with a greater force per unit area than atmosphericpressure; said channel having an opening therein; and a tube penetratingfrom the outside of the channel to the inside of the channel through theopening; and

a press coupled to the container to move the master shape into themembrane to shape a reformable material into the object according to themaster shape.

Augmented Reality/Virtual Reality Sports Gaming

FIG. 15 shows an exemplary 360 degree camera on a helmet, for example,for augmenting reality of sport games. Using augmented reality, variousways may exist for a user to “participate” in a live event. Generally,augmented reality refers to a presentation of a real world environmentaugmented with computer-generated data (such as sound, video, graphicsor other data). In some embodiments, augmented reality, implemented inconjunction with a live event, may allow a user to control a virtualobject that appears to compete or otherwise interact with theparticipants of the live event. For example, an end user device, such asa mobile phone, tablet computer, laptop computer, or gaming console maybe used to present a live video feed of an event to a user. This livevideo feed may be video of an event that is occurring in real-time,meaning the live event is substantially concurrently with thepresentation to the user (for example, buffering, processing, andtransmission of the video feed may result in a delay anywhere from lessthan a second to several minutes). The presentation of the live eventmay be augmented to contain one or more virtual objects that can be atleast partially controlled by the user. For instance, if the live eventis a stock car race, the user may be able to drive a virtual cardisplayed on the end user device to simulate driving in the live eventamong the actual racers. As such, the user may be able to virtually“compete” against the other drivers in the race. The virtual object, inthis example a car, may be of a similar size and shape to the real carsof the video feed. The user may be able to control the virtual car torace against the real cars present in the video feed. The real carsappearing in the video feed may affect the virtual object. For example,the virtual object may not be allowed to virtually move through a realcar on the augmented display, rather the user may need to drive thevirtual object around the real cars. Besides racing, similar principlesmay be applied to other forms of live events; for example, track andfield events (e.g., discus, running events, the hammer toss, polevaulting), triathlons, motorbike events, monster truck racing, or anyother form of event that a user could virtually participate in againstthe actual participants in the live event. In some embodiments, a usermay be able to virtually replay and participate in past portions of alive event. A user that is observing a live event may desire to attemptto retry an occurrence that happened during the live event. Whileviewing the live event, the user may be presented with or permitted toselect an occurrence that happened in the course of the live event andreplay it such that the user's input affects the outcome of at leastthat portion of the virtualized live event. Using a baseball game as anexample, with runners on first and third, two outs, and the count beingtwo balls and two strikes, the pitcher may throw a splitter,successfully striking out the batter with a pitch in the dirt. Theinning may end and the game may continue. The user may desire to replaythis unsuccessful at-bat with himself controlling the batter during thecommercial break. As such, via an end user device, the user may be ableto indicate the portion of the game he wishes to replay (e.g., the lastat-bat). Game facts from the live event may be used to virtuallyrecreate this at-bat for the user. For instance, the virtual game loadedby the user may use game facts leading up to the at-bat the user hasselected. For instance, the opposing team, the stadium, the score, thetime of day, the batter, the pitcher, and the sequence of pitches thrownby the pitcher may be used to provide the user with a virtual replay ofat least that portion of the baseball game that the user can affect viainput (e.g., swinging and aiming the virtual bat). In replaying theselected portion of the live event, the entire event may be virtualized.As such, referring to the baseball example, the pitcher, stadium, field,fielders, batter, and ball may all be replaced by virtual objects, withone (or more) of the virtual objects, such as the batter, beingcontrolled by the user. As such, this may resemble a video gameinstantiated with data from the live event. In some embodiments, aportion of the live event may involve a playback of a video feed of thelive event with a virtual object that is controlled by the user beingaugmented. Referring again to the example of the baseball game, thepitcher, stadium, fielders, and field may be replayed from the videofeed; the batter and/or ball may be virtualized. As such, the user maycontrol the batter and swing at a virtual ball that has taken the placeof the real ball present in the video feed. Besides baseball, suchreenactment of a portion of a live event may be applied to various formsof sporting events, such as football, soccer, tennis, golf, hockey,basketball, cricket, racing, skiing, gymnastics, and track and fieldevents. Other forms of live events, besides sports, may also bereenacted using such techniques.

FIG. 15A shows a multi-headed camera array 423 that may be at least partof a modular camera system, with each camera forming a module of themodular camera system. The camera array has a flexible structure so thatit is easy to remove a particular camera module from the camera arrayand to add new camera modules to the camera array. The camera modules inthe camera array may be configured in different geometries. For example,the camera array includes multiple camera modules arranged in a line, acylinder, a sphere, or another geometry. Each camera module may beconfigured to point to a different direction so that the camera arraymay capture an object or a scene from multiple directions at the sametime.

The camera system described herein may additionally include a set ofalgorithms for processing the video data captured by the camera array.The set of algorithms are stored on a non-transitory memory forconverting the input across multiple camera modules into a single streamof 3D video (e.g., a single compressed stream of 3D video data). The setof algorithms may be implemented in one or more “modules”. For example,the set of algorithms includes color correction algorithms for smoothingand correcting colors in the video data. In another example, the set ofalgorithms may be implemented in software that stitches the video datafrom multiple cameras into two large-format, panoramic video streams forleft and right eye viewing, and encodes and compresses the video using astandard MPEG format or other suitable encoding/compression format.

The camera array 423 may be constructed using various configurations.For example, the camera modules may be configured in differentgeometries (e.g., a sphere, a line, a cylinder, a cone, a cube, etc.)with the corresponding lenses 113 facing in different directions. Forexample, the camera modules are positioned within the camera array 423in a honeycomb pattern where each of the compartments form an aperturewhere a camera module may be inserted. In another example, the cameraarray 423 includes multiple lenses along a horizontal axis and a smallernumber of lenses on a vertical axis.

In some embodiments, the camera modules in the camera array 423 areoriented around a sphere in different directions with sufficientdiameter and field-of-view to capture enough view disparity to renderstereoscopic images.

The camera array 423 has a flexible structure so that a particularcamera module may be removed from the camera array 423 easily. In someembodiments, the camera modules are rotationally symmetrical such that acamera module may be inserted into the housing, removed, rotated 90degrees, and reinserted into the housing. In this example, the sides ofthe housing may be equidistant, such as a camera module with fourequidistant sides. This allows for a landscape orientation or a portraitorientation of the image frames without changing the base. In someembodiments, the lenses and the camera modules are interchangeable. Newcamera modules may also be added to the camera array 423. In someembodiments, the camera modules in the camera array 423 are positionedto have a sufficient field-of-view overlap so that all objects can beseen by more than one view point. In some embodiments, having the cameraarray 423 configured so that an object may be viewed by more than onecamera may be beneficial for correcting exposure or color deficienciesin the images captured by the camera array 423. Other benefits includedisparity/depth calculations, stereoscopic reconstruction, and thepotential to perform multi-camera high-dynamic range (HDR) imaging usingan alternating mosaic pattern of under- and over-exposure across thecamera array.

In some embodiments, the camera array 423 may also include a microphonearray for capturing sound from all directions. For example, themicrophone array may include a Core Sound Tetramic soundfieldtetrahedral microphone array following the principles of ambisonics,enabling reconstruction of sound from any arbitrary direction. Inanother example, the microphone array includes the Eigenmike, whichadvantageously includes a greater number of microphones and, as aresult, can perform higher-order (i.e. more spatially accurate)ambisonics. The microphone may be mounted to the top of the camera array423, be positioned between camera modules, or be positioned within thebody of the camera array 423. The result can then be rendered as animmersive video and a user can view the video with computer annotationsthereon for augmented reality purposes. In one implementation, the eventmay be a live event, for example, but is not limited to, a footballmatch, a cricket match, a basketball match, a theatre, a concert, andthe like. In one embodiment, the augmented reality content may include,but is not restricted to, live content associated with an event,recorded content associated with an event, a curated content, anadvertising content, or a combination thereof. In another embodiment,the augmented reality content may include, but is not restricted to,information related to a service available at an event, a venue of anevent, a status of a service, or a combination thereof. The system 100may also provide the augmented reality content associated with, but isnot restricted to, a venue of an event, duration of an event, a locationof an event, or a combination thereof, in another implementation.

One embodiment allows combined augmented reality and virtual reality onthe display. The method may include selectively allowing a transmissionof light from a local environment of the user based on a visualizationmode of the display object. The visualization mode may be one of anaugmented reality mode, a virtual reality mode, and a combination ofaugmented and virtual reality modes.

In another embodiment, sensors may be placed to track eye movement aswell as hand gestures and verbal commands. The method may furthercomprise capturing a field-of-view image of each of the user's eyes. Thecaptured field of view image may be used to estimate a head pose of theuser. The captured field-of-view image may be used to convert at leastone physical object to a physically rendered virtual object, and todisplay the physically rendered virtual object to the user. In anotherembodiment, sensors may be placed to track eye movement as well as handgestures and verbal commands. Then, a method comprises tracking amovement of a user's eyes, estimating a depth of focus of the user'seyes based on the tracked eye movement, modifying a light beamassociated with a display object based on the estimated depth of focussuch that the display object appears in focus, and projecting themodified light beam into the user's eyes. The diameter of the projectedlight beam projected to the user's eyes may be less than 0.7 mm.

For the athlete/participant who wish to enhance their gaming viaaugmented or virtual reality, features may include the following:

1. A method for using augmented reality, the method comprising:receiving, by a computerized device, a data stream with a 360 degreeview of a live event on each participant, wherein the data streamcomprises live video augmented with positions of team mates and opposingplayers and recommends a play routine based on live field condition andpositions of other players, wherein the user can select a point of viewfrom a selected participant.

2. The method for using augmented reality of claim 1, wherein the userplays in a virtual reality version of the live event.

3. The method for using augmented reality of claim 1, wherein the liveevent is a sporting event.

4. The method of claim 7, wherein the live event comprises: soccer,football, basketball, tennis, boxing, car racing, golf, ice hockey,badminton, volleyball, cycling, swimming, snooker, martial arts, rugby,motorbike, hockey, table tennis, horse racing, gymnastics, handball,figure skating, wrestling, skiing, diving, skating, archery, sailing,wrestling, fencing, equestrian, rowing, surfing, Beach Volleyball,Pool/Billiards, Lacrosse, Windsurfing, Polo, Tenpin Bowling,Racquetball, Competitive Climbing. Mountain Biking.

FIG. 15 shows an exemplary recommender to aid an athlete in improvingthe game. For example, the process can recommend a strategy in light ofthe opponent's historical performance. In tennis, a player's historicalweakness can be ascertained and a recommendation can be made to optimizesuccess. In a football example, a fourth down module 400 may include aFootball recommender, a Field Goal algorithm, and a Punt algorithm. TheFootball recommender determines the probability of each potential playoutcome associated with the Go For It coaching decision. The Field Goalalgorithm determines the probability of each potential play outcomeassociated with the Field Goal coaching decision. The Punt algorithm1102 determines the probability of each potential play outcomeassociated with the Punt coaching decision. As shown in FIG. 15B, theFootball recommender 402 determines the probability of each potentialplay outcome associated with the Go For It coaching decision on a fourthdown play. The Football recommender 402 receives an expected points (EP)input from the expected points module 300 at block 404, a yards to gain(YTG) for first down input at block 406, and a first down marker (FDM)yard line input at block 408. Preliminary Conversion Rate: At block 410,the Football recommender 402 uses the team's EP value from block 404 andthe YTG distance from block 406 to determine a preliminary first downconversion rate based on historical conversion data. Historical firstdown conversion data is shown in the form of a chart in FIG. 5, whereYTG distances are presented on the x-axis and average first downconversion rates are presented on the y-axis. This historical data showsthat the likelihood of a first down conversion decreases as the YTGdistance increases. Individual lines or equations may be presented toaccount for various EP values. For simplicity, FIG. 5 shows three linesto account for scenarios in which the offense and defense are an equalmatch with the same EP values (NEU), the offense has the advantage (OFFAD), and the defense has the advantage (DEF AD). The historical datapresented in FIG. 5 shows that stronger offenses will convert firstdowns versus weaker defenses (OFF AD) more often than weaker offenseswill convert first downs versus stronger defenses (DEF AD). Similarlines may be provided for specific EP values (e.g., 7-66 points). Bydetermining the first down conversion rate at each YTG distance for eachoffensive match-up, the Football recommender 402 is able to predict thelikelihood of a first down conversion with great precision.

Inside an opponent's 20-yard line (i.e., in the Red Zone), it becomesmore difficult to convert for a first down as the space on the fieldfrom which to work becomes more limited. As the FDM gets closer to theend zone and the YTG distance increases, the challenge of converting afirst down gets progressively more difficult versus similar scenariosoutside of the Red Zone. To account for the challenge of converting afirst down in the Red Zone, the Football recommender 402 may multiplythe preliminary conversion rate by a field position multiplier at block412 based on the YTG distance from block 406 and the FDM yard line fromblock 408 (where 100 represents the opponent's goal line. As an example,take a team that normally has a 50% fourth down conversion rate with 2YTG. If the team faces a fourth down play with 2 YTG outside of the RedZone, the conversion rate may remain at 50%. However, if the team facesa fourth down play with 2 YTG in the Red Zone, such as from theopponent's 2-yard line when the FDM is on the opponent's goal line(FDM=100), the normal 50% conversion rate may be multiplied by thecorresponding field position multiplier of 85.5% to arrive at a loweradjusted conversion rate of 42.7%. The process may adjust team's firstdown conversion rate at block 412 based on particular strengths of histeam. In one embodiment, the Football recommender 402 multiplies theconversion rate by one or more additional multipliers, such as a YTGmultiplier, which may be specified by the coach. As an example, a teamthat thrives on running the football might find that it convertsshort-yardage situations particularly well, because its offense isdesigned to consistently grind out short gains. However, the same teammay have particular difficulty in converting longer-yardage situationsbecause the offense isn't conducive to big plays. In this example, theYTG multiplier may be greater than 100% below 5 YTG to increase theconversion rate in short-yardage situations and less than 100% above 5YTG to decrease the conversion rate in long-yardage situations.Conversely, a team with an explosive offense may be particularlyeffective in converting long yardages but may not have the personnel toget short yardage. In this example, the YTG multiplier may be less than100% below 5 YTG to decrease the conversion rate in short-yardagesituations and greater than 100% above 5 YTG to increase the conversionrate in long-yardage situations. The Indianapolis Colts were a greatexample of this during much of the Peyton Manning era. They were verydangerous in long-yardage situations due to the quality of their passinggame, but due to a poor running game, they often failed to convert inshort-yardage scenarios. The Football recommender 402 may calculate theprobability of a turnover and defensive touchdown as a function of theEP value from block 404 and the FDM yard line from block 408. Thisprobability may be as low as about 0.1% and as high as about 0.5%. Atblock 414, the Football recommender 402 assigns probabilities to eachpotential conversion outcome. The Football recommender 402 may determinenot only the likelihood of a first down conversion at block 412, butalso how likely the team is to score points if the conversion issuccessful at block 416. After a successful conversion, the team couldget just enough yards to get the first down and still not score anypoints on the drive, or it could score a touchdown on the very same playor a subsequent play of the same drive. Therefore, the Footballrecommender 402 may take into account the potential upside of the driveshould the fourth down play be successful at any field position. Atblock 416, the Football recommender 402 uses the team's EP value fromblock 404 and the FDM yard line from block 408 to determine the pointsscored given conversion based on historical scoring data. Historicalscoring data is shown in the form of a chart in FIG. 6, where FDM yardlines are presented on the x-axis (with 0 representing the team's owngoal line and 100 representing the opponent's goal line) and averagepoints scored given conversion are presented on the y-axis. Thishistorical data shows that the likelihood of scoring points increases asthe FDM approaches the opponent's goal line. Individual lines orequations may be presented to account for various EP values. Forsimplicity, FIG. 6 shows three lines to account for scenarios in whichthe offense and defense are an equal match with the same EP values(NEU), the offense has the advantage (OFF AD), and the defense has theadvantage (DEF AD). The historical data presented in FIG. 6 shows thatstronger offenses will score more points versus weaker defenses (OFF AD)than weaker offenses will score versus stronger defenses (DEF AD).Similar lines may be provided for specific EP values (e.g., 7-66points). In this manner, the augmented reality system can enhance thegame.

For viewers who wish to participate via augmented or virtual reality,features may include the following:

1. A method for using augmented reality, the method comprising:receiving, by a computerized device, a data stream with a 360 degreeview of a live event on each participant, wherein the data streamcomprises live video, wherein: the live video comprises a live object;receiving, by the computerized device, input from a user, wherein theinput from the user affects behavior of a virtual object; andpresenting, by the computerized device, the live event augmented by thevirtual object, wherein a behavior of the live object of the live eventaffects the behavior of the virtual object and each participant, whereinthe user can select a point of view from a selected participant.

2. The method for using augmented reality of claim 1, wherein: thevirtual object is presented such that the virtual object appears tocompete with the live object.

3. The method for using augmented reality of claim 1, wherein the liveevent is a sporting event.

4. The method for using augmented reality of claim 1, furthercomprising: receiving, by the computerized device, data corresponding toa second virtual object from a remote computerized device; anddisplaying, by the computerized device, the live event augmented by thevirtual object further augmented with the second virtual object.

5. The method for using augmented reality of claim 4, wherein thebehavior of the second virtual object is affected by a second user.

6. The method for using augmented reality of claim 4, furthercomprising: modifying, by the computerized device, behavior of thevirtual object in response to the second virtual object.

7. A method for using augmented reality, the method comprising:receiving, by a computerized device, data corresponding to a live event;presenting, by the computerized device, the live event up to a point intime; presenting, by the computerized device, a virtual event at leastpartially based on an event that occurred during the live event earlierthan the point in time; receiving, by the computerized device, inputlinked with the virtual event, wherein the input is received from auser; and presenting, by the computerized device, an outcome of thevirtual event, wherein the outcome is at least partially based on theinput received from the user.

8. The method for using augmented reality of claim 7, wherein: thevirtual event is presented at least starting when the live event isstopped.

9. The method of claim 7, wherein the live event is a sporting event.

10. The method of claim 7, wherein the live event comprises: soccer,football, basketball, tennis, boxing, car racing, golf, ice hockey,badminton, volleyball, cycling, swimming, snooker, martial arts, rugby,motorbike, hockey, table tennis, horse racing, gymnastics, handball,figure skating, wrestling, skiing, diving, skating, archery, sailing,wrestling, fencing, equestrian, rowing, surfing, Beach Volleyball,Pool/Billiards, Lacrosse, Windsurfing, Polo, Tenpin Bowling,Racquetball, Competitive Climbing. Mountain Biking.

11. A method for using virtual reality, the method comprising:receiving, by a computerized device, a data stream with a 360 degreeview of a computer generated event on each participant, wherein the datastream comprises live video, wherein: the live video comprises a liveobject; receiving, by the computerized device, input from a user,wherein the input from the user affects behavior of a virtual object;and presenting, by the computerized device, the live event augmented bythe virtual object, wherein a behavior of the live object of the liveevent affects the behavior of the virtual object and each participant.

12. A method for using augmented reality and virtual reality, the methodcomprising: receiving, by a computerized device, a data stream with a360 degree view of a live event on each participant, wherein the datastream comprises live video, wherein: the live video comprises a liveobject; receiving, by the computerized device, input from a user,wherein the input from the user affects behavior of a virtual object;and presenting, by the computerized device, the live event augmented bythe virtual object, wherein a behavior of the live object of the liveevent affects the behavior of the virtual object and each participant,and wherein the virtual reality is rendered by switching the displayfrom an augmented view to a virtual reality view by fading out theaugmented view on the display to show only the virtual reality view andswitching back when augmented reality view is desired.

Moreover, the viewers can collaboratively read the situation andrecommend a strategy in real-time to improve viewer participation. Inthis manner,

1. A method for participating in a game, the method comprising:collecting from viewers of a game one or more state change events duringa game; determining whether a series of the collected state changeevents are a known pattern; requesting, when the series of the collectedstate change events is an unknown pattern, viewers of the game toidentify what caused the collected state change events; and judging, bythe viewers, a best reason among the identified causes of the collectedstate change events.

2. The method of claim 1, comprising running a lottery to decide whichrecommendation is used for the next play in the game.

3. The method of claim 1, further comprising: compensating at least oneviewer who is judged to have the best reason among the identified causesof the collected state change events.

4. The method of claim 1, further comprising: storing as the knownpattern, the best reason among the identified causes of the collectedstate change events when one of the pattern is repeated greater than athreshold number of repeats, and the number of the viewers who agreewith the corresponding best reason is greater than a threshold number ofusers.

5. The method of claim 4, further comprising: associating with thestored best reason a corrective action to be taken in response to afuture corresponding the collected state change events.

6. The method of claim 4, further comprising: displaying to the otherviewers and players, when the stored best reason is known, theoccurrence of the stored best reason.

7. The method of claim 5, further comprising: transmitting the storedbest reason to other viewers.

8. The method of claim 1, wherein the series of the collected statechange events are at least two state change events that occur within athreshold period of time from each other.

Recognition of Exercise Pattern and Tracking of Calorie Consumption

FIG. 16A illustrates the positions of a ski 126′ and skier 128′ during alofting maneuver on the slope 132′. The ski 126′ and skier 128′ speeddown the slope 132′ and launch into the air 136 at position “a,” andlater land at position “b” in accord with the well-known Newtonian lawsof physics. With an airtime sensor, described above, the unit 10calculates and stores the total airtime that the ski 126′ (and hence theskier 128′) experiences between the positions “a” and “b” so that theskier 128′ can access and assess the “air” time information. Airtimesensors such as the sensor 14 may be constructed with known components.Preferably, the sensor 14 incorporates either an accelerometer or amicrophone. Alternatively, the sensor 14 may be constructed as amechanical switch that detects the presence and absence of weight ontothe switch. Other airtime sensors 14 will become apparent in thedescription which follows. The accelerometer sensesvibration—particularly the vibration of a vehicle such as a ski ormountain bike—moving along a surface, e.g., a ski slope or mountain biketrail. This voltage output provides an acceleration spectrum over time;and information about airtime can be ascertained by performingcalculations on that spectrum. Based on the information, the system canreconstruct the movement path, the height, the speed, among others andsuch movement data is used to identify the exercise pattern. Forexample, the skier may be interested in practicing mogul runs, and thesystem can identify foot movement and speed and height information andpresent the information post exercises as feedback. Alternatively, thesystem can make live recommendations to improve performance to theathlete.

FIG. 16B illustrates a sensing unit 10″ mounted onto a mountain bike138. FIG. 16B also shows the mountain bike 138 in various positionsduring movement along a mountain bike race course 140 (for illustrativepurposes, the bike 138 is shown without a rider). At one location “c” onthe race course 140, the bike 138 hits a dirt mound 142 and catapultsinto the air 144. The bike 138 thereafter lands at location “d”. Asabove, with speed and airtime sensors, the unit 10 provides informationto a rider of the bike 138 about the speed attained during the ridearound the race course 140; as well as information about the airtimebetween location “c” and “d”. In this case, the system can recommend acadence to be reached by the rider, strengthen of abdominals, back andarms, for example.

For golf exercise, It is beneficial to require the golfer to swing thegolf club a plurality of times at each swing position to account forvariations in each swing. The swing position at which the golf club isswung can be determined by analysis of the measured accelerationprovided by the accelerometer, e.g., the time at which the accelerationchanges. Data obtained during the training stage may be entered into avirtual table of swing positions and estimated carrying distances for aplurality of different swing positions and a plurality of differentswings. A sample format for such a table is as follows, and includes theaveraged carrying distance for each of four different swing positions.The swing analyzer provides a golfer with an excellent estimation of thecarrying distance of a golf ball for a golf club swing at a specificswing position because it has been trained on actual swings by thegolfer of the same club and conversion of information about these swingsinto estimated carrying distances. The golfer can improve their golfgame since they can better select a club to use to hit a golf club fordifferent situations during a round of golf. Also, the swing pattern isused to identify each club path responsible for the curve of any shotand this information is used to improve the golfer. The direction of theclub path relative to the target, out-to-in (fade pattern) or in-to-out(draw pattern), is what I refer to as a players swing pattern. Playersthat swing from in-to-out will tend to hit draws and players that swingfrom out-to-in will tend to hit fades. Where the ball is struck on theface of the driver (strike point) can drastically alter the effect of aplayers swing pattern on ball flight. Thus, the camera detects where theball is struck, and a computer physics model of ball behavior ispresented to the golfer to improve the score. Shots struck off the heelwill tend to fade more or draw less and shots struck off the toe willtend to draw more or fade less. Thus, camera images of the shots struckof heel or toe can also be used to provide patternrecognition/prediction and for training purposes.

For tennis, examples of motions determined for improvement are detailednext. The system can detect if the continental grip is achieved.Throwing Action pattern is also detected, as the tennis serve is anupwards throwing action that would deliver the ball into the air if itwere a baseball pitch. Ball Toss improvements can be determined when theplayer lines the straight arm up with the net post and release the ballwhen your hand reaches eye level. The system checks the forwarddirection so the player can drive weight (and built up momentum) forwardinto the ball and into the direction of the serve.

The sensors can work with a soccer training module with kinematics ofball control, dribbling, passing, crossing, shooting, heading,volleying, taking throw-ins, penalties, corner kicks and free kicks,tackling, marking, juggling, receiving, shielding, clearing, and goalkeeping. The sensors can work with a basketball training module withkinematics of crossover dribble, behind back, pull back dribble, lowdribble, basic dribble, between legs dribble, Overhead Pass, Chest Pass,Push Pass, Baseball Pass, Off-the-Dribble Pass, Bounce Pass, Jump Shot,Dunk, Free throw, Layup, Three-Point Shot, Hook Shot. The sensors canwork with a baseball training module with kinematics of Hitting,Bunting, Base Running and Stealing, Sliding, Throwing, Fielding GroundBalls, Fielding Fly Balls, Double Plays and Relays, Pitching andCatching, Changing Speeds, Holding Runners, Pitching and PitcherFielding Plays, Catching and Catcher Fielding Plays.

For weight training, the sensor can be in gloves as detailed above, orcan be embedded inside the weight itself, or can be in a smart watch,for example. The user would enter an app indicating that the user isdoing weight exercises and the weight is identified as a dumbbell, acurl bar, and a bar bell. Based on the arm or leg motion, the systemautomatically detects the type of weight exercise being done. In oneembodiment shown in FIG. 15C, with motion patterns captured by glove andsock sensors, the system can automatically detect the followingexemplary exercise:

Upper Body:

-   -   Chest: Barbell Bench Presses, Barbell Incline Presses, Dumbbell        Bench Presses, Dumbbell Incline Presses, Dumbbell Flyes, Cable        Crossovers    -   Back: Pull-Ups, Wide-Grip Lat Pulldowns, One-Arm Dumbbell Rows,        Seated Cable Rows, Back Extensions, Straight Arm Pulldowns    -   Shoulders: Seated Dumbbell Presses, Front Raises, Lateral        Raises, Reverse Flyes, Upright Cable Rows, Upright Barbell Rows    -   Biceps: Alternate Dumbbell Curls, Barbell Curls, Preacher Curls,        Concentration Curls, Cable Curls, Hammer Curls    -   Triceps: Seated Triceps Presses, Lying Triceps Presses, Triceps        Kickbacks, Triceps Pushdowns, Cable Extensions, Bench Dips

Lower Body

-   -   Quadriceps: Barbell Squats, Leg Presses, Leg Extensions    -   Hamstrings: Dumbbell Lunges, Straight-Leg Deadlifts, Lying Leg        Curls    -   Calves: Seated Calf Raises, Standing Heel Raises

Abs: Floor Crunches, Oblique Floor Crunches, Decline Crunches, DeclineOblique, Hanging Knee Raises, Reverse Crunches, Cable Crunches, CableOblique Crunches

In one implementation in FIG. 16D, an HMM is used to track weightliftingmotor skills or sport enthusiast movement patterns. Human movementinvolves a periodic motion of the legs. Regular walking involves thecoordination of motion at the hip, knee and ankle, which consist ofcomplex joints. The muscular groups attached at various locations alongthe skeletal structure often have multiple functions. The majority ofenergy expended during walking is for vertical motion of the body. Whena body is in contact with the ground, the downward force due to gravityis reflected back to the body as a reaction to the force. When a personstands still, this ground reaction force is equal to the person's weightmultiplied by gravitational acceleration. Forces can act in otherdirections. For example, when we walk, we also produce friction forceson the ground. When the foot hits the ground at a heel strike, thefriction between the heel and the ground causes a friction force in thehorizontal plane to act backwards against the foot. This force thereforecauses a breaking action on the body and slows it down. Not only dopeople accelerate and brake while walking, they also climb and dive.Since reaction force is mass times acceleration, any such accelerationof the body will be reflected in a reaction when at least one foot is onthe ground. An upwards acceleration will be reflected in an increase inthe vertical load recorded, while a downwards acceleration will bereduce the effective body weight. Zigbee wireless sensors with tri-axialaccelerometers are mounted to the sport enthusiast on different bodylocations for recording, for example the tree structure as shown in FIG.16D. As shown therein, sensors can be placed on the four branches of thelinks connect to the root node (torso) with the connected joint, leftshoulder (LS), right shoulder (RS), left hip (LH), and right hip (RH).Furthermore, the left elbow (LE), right elbow (RE), left knee (LK), andright knee (RK) connect the upper and the lower extremities. Thewireless monitoring devices can also be placed on upper back body nearthe neck, mid back near the waist, and at the front of the right legnear the ankle, among others.

The sequence of human motions can be classified into several groups ofsimilar postures and represented by mathematical models calledmodel-states. A model-state contains the extracted features of bodysignatures and other associated characteristics of body signatures.Moreover, a posture graph is used to depict the inter-relationshipsamong all the model-states, defined as PG(ND,LK), where ND is a finiteset of nodes and LK is a set of directional connections between everytwo nodes. The directional connection links are called posture links.Each node represents one model-state, and each link indicates atransition between two model-states. In the posture graph, each node mayhave posture links pointing to itself or the other nodes.

In the pre-processing phase, the system obtains the human body profileand the body signatures to produce feature vectors. In the modelconstruction phase, the system generate a posture graph, examinefeatures from body signatures to construct the model parameters of HMM,and analyze human body contours to generate the model parameters ofASMs. In the motion analysis phase, the system uses features extractedfrom the body signature sequence and then applies the pre-trained HMM tofind the posture transition path, which can be used to recognize themotion type. Then, a motion characteristic curve generation procedurecomputes the motion parameters and produces the motion characteristiccurves. These motion parameters and curves are stored over time, and ifdifferences for the motion parameters and curves over time is detected,the system then runs the sport enthusiast through additional tests toconfirm the detected motion.

In one exemplary process for determining exercise in the left or righthalf of the body, the process compares historical left shoulder (LS)strength against current LS strength (3200). The process also compareshistorical right shoulder (RS) strength against current RS strength(3202). The process can compare historical left hip (LH) strengthagainst current LH strength (3204). The process can also comparehistorical right hip (RH) strength against current RH strength (3206).If the variance between historical and current strength exceedsthreshold, the process generates warnings (3208). Furthermore, similarcomparisons can be made for sensors attached to the left elbow (LE),right elbow (RE), left knee (LK), and right knee (RK) connect the upperand the lower extremities, among others.

The system can ask the sport enthusiast to squeeze a strength gauge,piezoelectric sensor, or force sensor to determine force applied duringsqueeze. The user holds the sensor or otherwise engages the sensor. Theuser then applies and holds a force (e.g., compression, torque, etc.) tothe sensor, which starts a timer clock and triggers a sampling startindicator to notify the user to continue to apply (maximum) force to thesensor. Strength measurements are then sampled periodically during thesampling period until the expiration of time. From the sampled strengthdata, certain strength measurement values are selected, such as themaximum value, average value(s), or values obtained during the samplingperiod. The user can test both hands at the same time, or alternativelyhe may test one hand at a time. A similar approach is used to sense legstrength, except that the user is asked to pushed down on a scale todetermine the foot force generated by the user.

In one embodiment, exercise motion data acquired by the accelerometer ormulti-axis force sensor is analyzed, as will be discussed below, inorder to determine the motion of each exercise stroke during theexercise session (i.e., horizontal vertical or circular). In anotherembodiment for detecting exercise motion using accelerometer, the firstminimum discovered during the scanning is noted as the first xmin andconsidered to be the start of the first brushstroke. The first maximum xvalue following the first minimum x value is located and construed to bethe middle of the first exercise stroke (where exercise motion changesfrom one direction to the other). The next xmin value indicates the endof the first brushstroke and the beginning of the next brushstroke. Thecomputer records the data for each brushstroke and continues on throughthe data to find the next brushstroke, recording each successive motionin memory. For the first brushstroke, the maximum and minimum values ofthe x coordinate (xmax and xmin) are determined. The Y-directionlengths, Ly1 and Ly2, between the data points just before and just aftereach of xmax and xmin (xmax+1, xmax−1, and Xmin+1, xmin−1) are thendetermined. The length Lx along the x axis, between xmax and xmin, isalso determined. Next, if Lx is less than 2 and either Ly1 or Ly2 isgreater than one, then the motion is construed to be vertical. If Ly1and Ly2 are both less than one, then the motion is construed to behorizontal. Otherwise, the motion is construed to be circular.

Data obtained from the gyroscope, if one is used, typically does notrequire a complex analysis. To determine which side of the mouth isbeing brushed at a particular time, the gyroscope data is scanned todetermine when the rotational orientation is greater than 180 degrees,indicating the left side, and when it is less than 180 degrees,indicating the right side. As explained above, top and bottom and gumbrushing information can also be obtained, without any calculations,simply by examining the data. The time sequence of data that is acquiredduring exercise and analyzed as discussed above can be used in a widevariety of ways.

In one embodiment, the accelerometers distinguish between lying down andeach upright position of sitting and standing based on the continuousoutput of the 3D accelerometer. The system can detect (a) extended timein a single position; (b) extended time sitting in a slouching posture(kyphosis) as opposed to sitting in an erect posture (lordosis); and (c)repetitive stressful movements, such as may be found on somemanufacturing lines, while typing for an extended period of time withoutproper wrist support, or while working all day at a weight liftingexercise, among others. In one alternative embodiment, angular positionsensors, one on each side of the hip joint, can be used to distinguishlying down, sitting, and standing positions. In another embodiment, thesystem repeatedly records position and/or posture data over time. In oneembodiment, magnetometers can be attached to a thigh and the torso toprovide absolute rotational position about an axis coincident withEarth's gravity vector (compass heading, or yaw). In another embodiment,the rotational position can be determined through the in-doorpositioning system as discussed above.

To improve a golf swing, the complex motion of the body first startswith the stance. The system checks that the golfer has a low center ofgravity to remain balanced throughout the swing path. The swing startswith the arms moving back in a straight line. When the club head reachesthe level of the hip, two things happen: there is a stern wrist cockthat acts as a hinge along with the left knee (for a right handedswing), building up its torque by moving into the same line as the bellybutton before the start of the upswing. As the swing continues to thetop of the backswing (again for right handed golf swing), the golfer'sleft arm should be perfectly straight and his right arm should be hingedat the elbow. The downswing begins with the hips and the lower bodyrather than the arms and upper body, with emphasis on the wrist cock. Asthe golfer's hips turn into the shot, the right elbow will drop straightdown, hugging the right side of the golfer's torso. As the right elbowdrops, the wrists begin to snap through from the wrist cock in thebackswing. A solid extension of the arms and good transfer of bodyshould put the golfer leaning up on his right toe, balanced, with thegolf club resting on the back of the golfers neck. Importantly, all ofthe movements occur with precise timing, while the head remainscompletely still with eyes focused on the ball throughout the entireswing.

The system can identify illnesses and prevent overexertion leading toillnesses such as a stroke. Depending on the severity of the stroke,sport enthusiasts can experience a loss of consciousness, cognitivedeficits, speech dysfunction, limb weakness, hemiplegia, vertigo,diplopia, lower cranial nerve dysfunction, gaze deviation, ataxia,hemianopia, and aphasia, among others. Four classic syndromes that arecharacteristically caused by lacunar-type stroke are: pure motorhemiparesis, pure sensory syndrome, ataxic hemiparesis syndrome, andclumsy-hand dysarthria syndrome. Sport enthusiasts with pure motorhemiparesis present with face, arm, and leg weakness. This conditionusually affects the extremities equally, but in some cases it affectsone extremity more than the other. The most common stroke location inaffected sport enthusiasts is the posterior limb of the internalcapsule, which carries the descending corticospinal and corticobulbarfibers. Other stroke locations include the pons, midbrain, and medulla.Pure sensory syndrome is characterized by hemibody sensory symptoms thatinvolve the face, arm, leg, and trunk. It is usually the result of aninfarct in the thalamus. Ataxic hemiparesis syndrome features acombination of cerebellar and motor symptoms on the same side of thebody. The leg is typically more affected than the arm. This syndrome canoccur as a result of a stroke in the pons, the internal capsule, or themidbrain, or in the anterior cerebral artery distribution. Sportenthusiasts with clumsy-hand dysarthria syndrome experience unilateralhand weakness and dysarthria. The dysarthria is often severe, whereasthe hand involvement is more subtle, and sport enthusiasts may describetheir hand movements as “awkward.” This syndrome is usually caused by aninfarct in the pons. Different patterns of signs can provide clues as toboth the location and the mechanism of a particular stroke. The systemcan detect symptoms suggestive of a brainstem stroke include vertigo,diplopia, bilateral abnormalities, lower cranial nerve dysfunction, gazedeviation (toward the side of weakness), and ataxia. Indications ofhigher cortical dysfunction-such as neglect, hemianopsia, aphasia, andgaze preference (opposite the side of weakness)-suggest hemisphericdysfunction with involvement of a superficial territory from anatherothrombotic or embolic occlusion of a mainstem vessel or peripheralbranch.

To detect muscle weakness or numbness, in one embodiment, the systemapplies a pattern recognizer such as a neural network or a Hidden MarkovModel (HMM) to analyze accelerometer output. In another embodiment,electromyography (EMG) is used to detect muscle weakness. In anotherembodiment, EMG and a pattern analyzer is used to detect muscleweakness. In yet another embodiment, a pattern analyzer analyzes bothaccelerometer and EMG data to determine muscle weakness. In a furtherembodiment, historical ambulatory information (time and place) is usedto further detect changes in muscle strength. In yet other embodiments,accelerometer data is used to confirm that the sport enthusiast is atrest so that EMG data can be accurately captured or to compensate formotion artifacts in the EMG data in accordance with a linear ornon-linear compensation table. In yet another embodiment, the EMG datais used to detect muscle fatigue and to generate a warning to the sportenthusiast to get to a resting place or a notification to a nurse orcaregiver to render timely assistance. The amplitude of the EMG signalis stochastic (random) in nature and can be reasonably represented by aGausian distribution function. The amplitude of the signal can rangefrom 0 to 10 mV (peak-to-peak) or 0 to 1.5 mV (rms). The usable energyof the signal is limited to the 0 to 500 Hz frequency range, with thedominant energy being in the 50-150 Hz range. Usable signals are thosewith energy above the electrical noise level. The dominant concern forthe ambient noise arises from the 60 Hz (or 50 Hz) radiation from powersources. The ambient noise signal may have an amplitude that is one tothree orders of magnitude greater than the EMG signal. There are twomain sources of motion artifact: one from the interface between thedetection surface of the electrode and the skin, the other from movementof the cable connecting the electrode to the amplifier. The electricalsignals of both noise sources have most of their energy in the frequencyrange from 0 to 20 Hz and can be reduced.

In one embodiment, the camera captures facial expression and a code suchas the Microsoft Emotion API takes a facial expression in an image as aninput, and returns the confidence across a set of emotions for each facein the image, as well as bounding box for the face, using the Face API.The emotions detected are anger, contempt, disgust, fear, happiness,neutral, sadness, and surprise. These emotions are understood to becross-culturally and universally communicated with particular facialexpressions. Alternatively, a marker for emotional arousal is galvanicskin response (GSR), also referred to as skin conductance (SC) orelectro-dermal activity (EDA). EDA modulates the amount of sweatsecretion from sweat glands. The amount of sweat glands varies acrossthe human body, being highest in hand and foot regions (200-600 sweatglands per cm2). While sweat secretion plays a major role forthermoregulation and sensory discrimination, changes in skin conductancein hand and foot regions are also triggered quite impressively byemotional stimulation: the higher the arousal, the higher the skinconductance. It is noteworthy to mention that both positive (“happy” or“joyful”) and negative (“threatening” or “saddening”) stimuli can resultin an increase in arousal—and in an increase in skin conductance. Skinconductance is not under conscious control. Instead, it is modulatedautonomously by sympathetic activity which drives human behavior,cognitive and emotional states on a subconscious level. Skin conductancetherefore offers direct insights into autonomous emotional regulation.It can be used as alternative to self-reflective test procedures,or—even better—as additional source of insight to validate verbalself-reports or interviews of a respondent. Based on the detectedemotion, the exercise can be increased, decreased, or stoppedaltogether.

Features of the auto-detection of exercise include the following:

1. An exercise system, comprising:

-   -   a processor running the motion analyzer and coupled to a        wireless transceiver;    -   an accelerometer coupled to the processor; and    -   a kinematic motion analysis module executed by the processor to        detect exercise type.

2. The system of claim 1, comprising a plurality of smart modulesmounted on an exerciser forming a mesh network.

3. The system of claim 1 where the electronic components, sensors, andinterconnects of the system monitor, record, process and/or transmitevents of interest (such as accelerometers and gyroscopes for impactevents, temperature sensors for temperature and/or temperaturegradients, pressure sensors, moisture sensors, chemical sensors).

4. The system of claim 1 comprised for sensing and/or monitoring impactevents where the sensors are accelerometers, gyroscopes, and/or pressuresensors.

5. The system of claim 1 comprised for sensing and/or monitoring and/orcontrolling ongoing events where the sensors monitor temperature,temperature gradients, motion, position, environmental or chemicallevels, or other such information.

6. The system of claim 1 comprised for sensing events or otherinformation including mounting multiple distributed sensors forobtaining spatial and/or temporal distribution in the data and/ormultiple sensors sensing different information and data.

7. The system of claim 1 comprising a camera and an image recognitionmodule to determine kinematic movement.

8. The system of claim 1 including a statistical recognizer to determinekinematic movement.

9. The system of claim 8, comprising a model-state that contains theextracted features of body signatures and other associatedcharacteristics of body signatures.

10. The system of claim 1 comprising links connecting a root node(torso) with connected joint, left shoulder (LS), right shoulder (RS),left hip (LH), and right hip (RH), and left elbow (LE), right elbow(RE), left knee (LK), and right knee (RK) connect upper and lowerextremities.

11. The system of claim 1 comprising a posture detection module.

12. The system of claim 1, comprising a module to detect a lying downstate and a standing state.

13. The system of claim 1, comprising a hidden markov model module todetect muscle movement and exercise pattern.

14. The system of claim 1 comprising optimizing tennis shots to improveserve, groundstroke, volley, half volley, smash, forehand, backhand,flat, side spin, block, slice, topspin shot, lob, passing shot,dropshot, cross-court shot, down-the-line shot.

15. The system of claim 1, comprising an electromyography (EMG) sensorto detect muscle strength or weakness.

16. The system of claim 1, comprising an emotion detector wherein anexercise can be increased, decreased, or stopped based on detectedemotion.

17. The system of claim 17, wherein the detector comprises videodetection of faces or a GSR sensor.

18. The system of claim 1 comprising a cloud storage to receive sensordata.

19. The system of claim 1, comprising a golf training module that checksthat a golfer has a low center of gravity to remain balanced throughouta swing path, that a swing starts with the arms moving back in astraight line, and when a club head reaches the level of the hip, awrist cock acts as a hinge along with the left knee (for a right handedswing), building up torque by moving into the same line as the bellybutton before the start of the upswing. As the swing continues to thetop of the backswing (again for right handed golf swing), the golfer'sleft arm is straight and a right arm is hinged at the elbow.

20. The system of claim 19, wherein the golf training module checks thata downswing begins with the hips and the lower body and as the golfer'ships turn into the shot, the right elbow drops down, hugging the rightside of the golfer's torso and wrists begin to snap through from thewrist cock in the backswing.

21. The system of claim 1, comprising a soccer training module withkinematics of ball control, dribbling, passing, crossing, shooting,heading, volleying, taking throw-ins, penalties, corner kicks and freekicks, tackling, marking, juggling, receiving, shielding, clearing, andgoalkeeping.

22. The system of claim 1, comprising a basketball training module withkinematics of crossover dribble, behind back, pull back dribble, lowdribble, basic dribble, between legs dribble, Overhead Pass, Chest Pass,Push Pass, Baseball Pass, Off-the-Dribble Pass, Bounce Pass, Jump Shot,Dunk, Free throw, Layup, Three-Point Shot, Hook Shot.

23. The system of claim 1, comprising a baseball training module withkinematics of Hitting, Bunting, Base Running and Stealing, Sliding,Throwing, Fielding Ground Balls, Fielding Fly Balls, Double Plays andRelays, Pitching and Catching, Changing Speeds, Holding Runners,Pitching and Pitcher Fielding Plays, Catching and Catcher FieldingPlays.

Data from multiple exercise sessions may be collected and used tocompile a history of the user's habits over an extended period of time,enabling the user's trainer to better understand user compliance issues.The trainer can review the data with the user and view the animations ofthe user's exercise sessions during an office visit, allowing thetrainer to better instruct the user in proper brushing technique. Thetrainer can also review the patient's brushing history over time, todetermine whether the patient's exercise technique is improving.

The sensor 14 can be integrated into objects already associated with thesporting activity. In one aspect, the sensing unit is integrated intothe ski boot or other boot. In another aspect, the sensing unit isintegrated into the binding for a ski boot or snowboarder boot. In stillanother aspect, the sensing unit is integrated into a ski, snowboard,mountain bike, windsurfer, windsurfer mast, roller blade boot,skate-board, kayak, or other sport vehicle. Collectively, the sportobjects such as the ski boot and the variety of sport vehicles aredenoted as “sport implements”. Accordingly, when the sensing unit is not“stand alone”, the housing which integrates the controller subsystemwith one or more sensors and battery can be made from the material ofthe associated sport implement, in whole or in part, such that thesensing unit becomes integral with the sport implement. The universalinterface is therefore not desired in this aspect.

One skilled in the art will appreciate that, for this and otherprocesses and methods disclosed herein, the functions performed in theprocesses and methods may be implemented in differing order.Furthermore, the outlined steps and operations are only provided asexamples, and some of the steps and operations may be optional, combinedinto fewer steps and operations, or expanded into additional steps andoperations without detracting from the essence of the disclosedembodiments.

The embodiments described herein may include the use of a specialpurpose or general-purpose computer including various computer hardwareor software modules, as discussed in greater detail below.

Embodiments described herein may be implemented using computer-readablemedia for carrying or having computer-executable instructions or datastructures stored thereon. Such computer-readable media may be anyavailable media that may be accessed by a general purpose or specialpurpose computer. By way of example, and not limitation, suchcomputer-readable media may include tangible computer-readable storagemedia including RAM, ROM, EEPROM, CD-ROM or other optical disk storage,magnetic disk storage or other magnetic storage devices, or any otherstorage medium which may be used to carry or store desired program codein the form of computer-executable instructions or data structures andwhich may be accessed by a general purpose or special purpose computer.Combinations of the above may also be included within the scope ofcomputer-readable media. Computer-executable instructions comprise, forexample, instructions and data which cause a general purpose computer,special purpose computer, or special purpose processing device toperform a certain function or group of functions. Although the subjectmatter has been described in language specific to structural featuresand/or methodological acts, it is to be understood that the subjectmatter defined in the appended claims is not necessarily limited to thespecific features or acts described above. Rather, the specific featuresand acts described above are disclosed as example forms of implementingthe claims. As used herein, the term “module” or “component” may referto software objects or routines that execute on the computing system.The different components, modules, engines, and services describedherein may be implemented as objects or processes that execute on thecomputing system (e.g., as separate threads). While the system andmethods described herein may be preferably implemented in software,implementations in hardware or a combination of software and hardwareare also possible and contemplated. In this description, a “computingentity” may be any computing system as previously defined herein, or anymodule or combination of modulates running on a computing system. Allexamples and conditional language recited herein are intended forpedagogical objects to aid the reader in understanding the invention andthe concepts contributed by the inventor to furthering the art, and areto be construed as being without limitation to such specifically recitedexamples and conditions. Although embodiments of the present inventionshave been described in detail, it should be understood that the variouschanges, substitutions, and alterations could be made hereto withoutdeparting from the spirit and scope of the invention.

1. A board, comprising: a body; a processor coupled to a wirelesstransceiver; a camera coupled to the elongated body to detect distancefrom another object; and an accelerometer disposed within the elongatedbody to detect acceleration of the board.
 2. The board of claim 1,wherein at least one sensor selected from a sensor set comprising: apressure sensor configured to detect at least one pressure event at anexternal surface location; a motion sensor configured to detect at leastone motion event of the board; a digit motion sensor configured todetect at least one motion event of at least one digit of the user; atemperature sensor configured to detect a temperature at an externalsurface location.
 3. The board of claim 1, comprising an EKG sensor. 4.The board of claim 1, comprising a hand exercise regimen selected from ahand exercise regimen set comprising at least one of: a physical therapyhand exercise regimen; a physical training hand exercise regimen; or aphysical performance hand exercise regimen.
 5. The board of claim 1,comprising a gesture identifying component configured to identify atleast one hand gesture detected by at least one sensor; the memoryconfigured to, upon receiving an indication of a hand gesture identifiedby the gesture identifying component, store data corresponding to thehand gesture in the memory; and the device interface configured to, uponconnecting to the device, provide at least some of the stored datacorresponding to the hand gesture to the device.
 6. The board of claim1, comprising a plurality of foot receptacles, each having a sensor. 7.The board of claim 1, comprising a sensor worn by an opponent inwireless communication with the processor to communicate the force of animpact from the board.
 8. The board of claim 1, wherein the bodycomprises a snowboarding body, a surfing board body, a ski body,wakeboarding body, windsurfing body, paddle board body, balance boardbody, mountain boarding body, or water ski body.
 9. The board of claim1, comprising a hidden markov model module to detect muscle movement andexercise pattern.
 10. The board of claim 1, comprising an emotiondetector wherein an exercise is increased, decreased, or stopped basedon detected emotion.
 11. A system for a board, comprising: anaccelerometer disposed in the board for measuring a force of impact ofhitting the board; a radio frequency transmitter disposed in the boardand coupled to the accelerometer for transmitting impact measurements; acamera; a radio frequency receiver for receiving the impactmeasurements; and a display coupled to the radio frequency receiver fordisplaying the measured impacts.
 12. The system of claim 11, wherein atleast one sensor selected from a sensor set comprising: a pressuresensor configured to detect at least one pressure event at a board bodyexternal surface location; a board motion sensor configured to detect atleast one motion event of the board; a digit motion sensor configured todetect at least one motion event of at least one digit of the user; atemperature sensor configured to detect a temperature at an externalsurface location.
 13. The system of claim 11, comprising a biometricsensor.
 14. The system of claim 11, comprising a hand exercise regimenselected from a hand exercise regimen set comprising at least one of: aphysical therapy hand exercise regimen; a physical training handexercise regimen; or a physical performance hand exercise regimen. 15.The system of claim 11, wherein the board comprises a gestureidentifying component configured to identify at least one hand gesturedetected by at least one sensor; the memory configured to, uponreceiving an indication of a hand gesture identified by the gestureidentifying component, store data corresponding to the hand gesture inthe memory; and the device interface configured to, upon connecting tothe device, provide at least some of the stored data corresponding tothe hand gesture to the device.
 16. The system of claim 11, comprising aplurality of foot receptacles, each having a sensor.
 17. The system ofclaim 11, comprising a sensor worn by an opponent in wirelesscommunication with the processor to communicate the force of an impactfrom the board.
 18. The system of claim 11, wherein the body comprises asnowboarding body, a surfing board body, a ski body, wakeboarding body,windsurfing body, paddle board body, balance board body, mountainboarding body, or water ski body.
 19. The system of claim 11, comprisinga hidden markov model module to detect muscle movement and exercisepattern.
 20. The system of claim 11, comprising an emotion detectorwherein an exercise is increased, decreased, or stopped based ondetected emotion.